This procedure covers the removal and replacement of both front CV axles on the 2024 Rivian EDV 500 Dual Motor AWD electric delivery van.

Warnings

Tools required

Parts

• Front CV axle assembly (driver side) × 1 — Use OEM Rivian specification
• Front CV axle assembly (passenger side) × 1 — Use OEM Rivian specification
• Front axle hub nut (32mm) × 2 — Use OEM specification, single-use
• Differential seal ring/gasket × 2 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Open hood and disconnect 12V battery negative terminal
4. Wait minimum 5 minutes for high voltage system to discharge capacitors
5. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
6. Loosen but do not remove 32mm axle hub nuts on both front wheels while vehicle is on ground
7. Raise front of vehicle using floor jack at designated front lift points
8. Support vehicle on jack stands at frame rails behind front suspension
9. Remove front wheels completely
10. Place drain pan under front differential area

Procedure

1. 1

   Remove driver side axle hub nut and suspension components
   With vehicle supported on jack stands, fully remove the 32mm axle hub nut from the driver side. Remove the brake caliper mounting bolts and secure caliper to suspension with wire or zip ties without stressing brake hose. Remove the lower ball joint pinch bolt or control arm connection to gain clearance for axle removal. Leave the rotor in place initially to protect hub threads.
2. 2

   Separate driver side CV axle from hub assembly
   Remove the brake rotor. Thread the old axle nut back onto the axle shaft 2-3 turns to protect threads. Using a plastic dead blow hammer, strike the axle nut to break the splines free from the hub bearing. If axle is seized, use a CV axle puller threaded into the hub to press the axle out. Once free, remove the protective nut and slide the axle outward from the hub.
3. 3

   Remove driver side inboard CV joint from differential
   Position drain pan directly under the driver side CV axle inboard joint at the differential. Using a pry bar positioned against the differential housing, carefully pry the inboard CV joint straight out from the differential. The joint is retained by a circlip and will release with firm pressure. Once the circlip releases, pull the entire axle assembly out. Allow differential fluid to drain into pan. Inspect the differential seal for damage.
4. 4

   Remove passenger side axle hub nut and suspension components
   Repeat the process for the passenger side: fully remove the 32mm axle hub nut. Remove the brake caliper mounting bolts and secure caliper safely. Remove the lower ball joint pinch bolt or control arm connection. Remove the brake rotor to access the hub.
5. 5

   Separate passenger side CV axle from hub assembly
   Thread the old passenger side axle nut back onto the shaft 2-3 turns for protection. Use a plastic dead blow hammer to strike the nut and break the splines free from the hub bearing. If necessary, use the CV axle puller. Once freed, remove the protective nut and slide the axle outward from the hub assembly.
6. 6

   Remove passenger side inboard CV joint from differential
   Reposition the drain pan under the passenger side inboard CV joint. Using the pry bar against the differential housing, pry the inboard joint straight out until the retaining circlip releases. Remove the complete axle assembly. Additional fluid will drain from the differential. Inspect the differential seal and mating surface.
7. 7

   Clean and inspect differential housing
   With both axles removed, use a wire brush to clean the differential output shaft seal surfaces and mating areas. Inspect for wear, scoring, or damage. Check that old circlips are not remaining in the differential. Install new differential seal rings or gaskets per manufacturer specifications. Clean any metal debris from the differential housing opening using a lint-free cloth.
8. 8

   Install driver side CV axle inboard joint
   Verify the new driver side CV axle has the correct length and spline configuration for the driver side position (axles may be side-specific). Ensure the new circlip is properly seated in the groove on the inboard CV joint stub shaft. Align the splines and firmly push the inboard joint into the differential until the circlip audibly clicks into place. Tug on the axle to verify it is fully locked and will not pull out.
9. 9

   Install driver side CV axle into hub assembly
   Guide the outer CV joint stub shaft through the hub bearing, carefully aligning the splines. Push the axle through until it is fully seated and the outer end protrudes through the hub. Install the new 32mm axle hub nut and hand tighten only at this stage. Do not torque yet.
10. 10

    Install passenger side CV axle inboard joint
    Verify the new passenger side CV axle is correct for the passenger side (check part number and length). Ensure the circlip is properly installed on the inboard joint. Align the splines and push the inboard joint firmly into the differential until the circlip clicks into place. Pull on the axle to confirm it is locked securely.
11. 11

    Install passenger side CV axle into hub assembly
    Align the passenger side outer CV joint splines with the hub bearing and push through until fully seated. Install the new 32mm axle hub nut and hand tighten. Do not torque at this stage.
12. 12

    Reconnect suspension components both sides
    Install brake rotors on both sides. Reconnect the lower ball joints or control arm connections on both sides, installing all fasteners per factory specifications. Install brake calipers and tighten mounting bolts. Ensure all suspension components are properly aligned and all fasteners are secure.
13. 13

    Refill front differential
    Locate the front differential fill plug. Using a fluid pump or squeeze bottle, refill the front differential with 1.5 quarts of 75W-90 GL-5 gear oil or until fluid reaches the bottom of the fill hole. Install and tighten the fill plug. Wipe away any excess fluid.
14. 14

    Torque axle hub nuts and reinstall wheels
    With vehicle still on jack stands, have an assistant apply the brake pedal or use a pry bar to prevent hub rotation. Torque both 32mm axle hub nuts to manufacturer specification (typically 180-220 ft-lb for this application, verify in service manual). Install front wheels and hand tighten lug nuts.
15. 15

    Lower vehicle and final torque
    Carefully lower the vehicle to the ground and remove jack stands. With vehicle weight on wheels, torque wheel lug nuts to specification in a star pattern. Reconnect the 12V battery negative terminal.

Reassembly

1. All suspension fasteners must be torqued to specification with vehicle weight on suspension
2. Verify brake calipers are properly secured and brake hoses are not twisted or stressed
3. Check that no tools or parts were left in wheel wells or under vehicle
4. Confirm differential fluid level is correct and fill plug is tight

Verification

• Start vehicle and verify no warning lights related to drivetrain or ABS appear on dash
• Test drive at low speed in a safe area, checking for clicking, popping, or vibration from front axles
• Turn steering wheel full lock in both directions while driving slowly to verify CV joints operate smoothly
• Check for fluid leaks around differential seals after test drive
• Verify proper AWD engagement and normal acceleration with no driveline binding
• Re-check axle hub nut torque and wheel lug nut torque after 50 miles of driving

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