This procedure covers the removal and replacement of the inner CV boot on a 2024 Rivian EDV 500 dual motor AWD electric delivery vehicle, requiring partial disassembly of the drive axle assembly.

Warnings

Tools required

Parts

• Inner CV boot kit with clamps × 1 — Use OEM specification for Rivian EDV
• CV joint grease (included in boot kit or separate) × 1 — Molybdenum disulfide CV grease
• Axle nut (single use) × 1 — Use OEM specification
• Differential drain plug washer × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Verify which axle requires inner CV boot replacement (front left, front right, rear left, or rear right)
2. Disconnect 12V battery negative terminal and wait 2 minutes for system discharge
3. Follow manufacturer procedures to disable high voltage system and apply lockout/tagout devices
4. Raise vehicle on lift or safely support on jack stands at manufacturer-specified lift points
5. Remove wheel and tire assembly from affected corner
6. Place drain pan under differential on affected axle
7. Remove differential drain plug and drain gear oil completely
8. Inspect drained fluid for metal particles indicating internal differential damage

Procedure

1. 1

   Remove axle nut and loosen suspension components
   Remove the center axle nut from the hub assembly. This nut is typically single-use and should be replaced. Mark the position of any alignment-critical components before removal. Remove or loosen the lower control arm ball joint fastener to allow suspension movement for axle removal.
2. 2

   Disconnect outer CV joint from hub
   Push the axle shaft inward through the hub bearing to disengage the splines. If the axle is stuck, use a brass drift and hammer to tap it free from behind the hub. Do not damage the wheel speed sensor or hub bearing during this process. Support the outer end of the axle to prevent damage to the outer CV joint.
3. 3

   Remove inner CV joint from differential
   Position a pry bar between the inner CV joint housing and the differential case. Apply firm, steady pressure to separate the inner joint from the differential output shaft. You should feel and hear a distinct 'pop' when the circlip releases. Alternatively, use a slide hammer with axle puller attachment if the joint is seized. Pull the entire axle assembly away from the vehicle.
4. 4

   Secure axle and remove outer CV boot clamps
   Mount the axle assembly in a vise using the shaft (not the CV joint housings). Use CV boot clamp pliers or side cutters to remove both clamps from the outer CV boot. Slide the outer boot toward the center of the shaft to expose the inner CV joint area. Do not disassemble the outer CV joint unless it also requires service.
5. 5

   Remove inner CV boot clamps
   Cut or release both clamps securing the inner CV boot - one at the joint housing and one at the axle shaft. Use care not to damage the axle shaft surface, as this will cause premature boot failure. Slide the damaged inner boot toward the center of the axle.
6. 6

   Disassemble inner CV joint
   Mark the orientation of the inner CV joint housing relative to the axle shaft using a paint marker or scribe. Remove the circlip or retaining ring that secures the joint to the shaft. Slide the inner joint housing off the axle shaft. Remove the tripod or ball-type joint assembly from the shaft, noting the orientation. Some designs use a snap ring to retain the joint components.
7. 7

   Clean and inspect components
   Thoroughly clean all old grease from the inner CV joint housing, tripod/ball assembly, and axle shaft using solvent and clean towels. Inspect the joint for wear, pitting, or damage. Check the axle shaft splines and sealing surfaces for damage or corrosion. Replace the entire axle if joint wear is excessive or shaft damage is present. Wire brush any corrosion from the shaft boot sealing area.
8. 8

   Install new inner CV boot onto shaft
   Slide the new inner CV boot onto the axle shaft from the inner end, with the small end toward the center of the shaft. Position the boot in the groove on the axle shaft but do not clamp yet. Ensure the boot is not twisted and sits properly in its designated groove.
9. 9

   Reassemble inner CV joint with grease
   Pack approximately half of the supplied CV joint grease into the inner joint housing. Reinstall the tripod or ball-type joint assembly onto the axle shaft in the original orientation, securing with the snap ring or circlip. Pack the remaining grease around and into the joint assembly. Slide the joint housing over the assembly, aligning the marks made during disassembly.
10. 10

    Position and clamp inner CV boot
    Slide the inner CV boot over the joint housing and into the housing groove. Ensure the boot is not twisted and is properly seated in both the shaft groove and housing groove. Relieve any air pressure by carefully lifting the boot edge. Install the new boot clamps using the appropriate clamp tool. Tighten clamps securely - fold-over type clamps should be compressed until the locking tabs engage fully.
11. 11

    Reinstall outer CV boot clamps
    Slide the outer CV boot back into position over its joint. Ensure it is properly seated in both grooves. Install new clamps and secure them properly. Verify both boots are correctly positioned and sealed before reinstalling the axle.
12. 12

    Install axle assembly into differential
    Apply a thin coat of gear oil to the inner CV joint splines. Align the inner CV joint with the differential output shaft and push firmly until the circlip engages with an audible click. Tug on the axle to verify it is fully seated and locked in place.
13. 13

    Connect outer CV joint to hub
    Guide the outer CV joint splines through the hub bearing and into the hub. Install a new axle nut and thread it by hand initially. Do not fully torque yet. Reconnect the lower control arm ball joint and any other suspension components removed during disassembly.
14. 14

    Refill differential and torque fasteners
    Install a new differential drain plug washer and reinstall the drain plug. Refill the differential with the appropriate amount of 75W-90 GL-5 gear oil (1.5 quarts for front differential, 2.0 quarts for rear). Verify level at fill plug. With vehicle weight on suspension or brakes applied to prevent rotation, torque the axle nut to specification. Torque all suspension fasteners. Note: Specific torque values should be obtained from manufacturer service information as they are not available in the database.

Reassembly

1. Reinstall wheel and tire assembly, torquing lug nuts to specification in a star pattern
2. Remove lockout/tagout devices and restore high voltage system per manufacturer procedures
3. Reconnect 12V battery negative terminal
4. Lower vehicle to ground

Verification

• Test drive vehicle at various speeds and listen for clicking, popping, or grinding noises from the repaired axle during acceleration, deceleration, and turning
• Perform a visual inspection of the CV boot installation to verify proper seating and no leaks
• Inspect differential for leaks at drain plug and axle seal
• Verify no warning lights or fault codes related to wheel speed sensors or drivetrain components
• Check that steering operates normally with no binding or unusual resistance

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