Replace the outer CV boot on a 2024 Rivian EDV 500 to prevent contamination and maintain CV joint integrity.

Warnings

Tools required

Parts

• Outer CV boot kit with clamps × 1 — Use OEM specification
• CV joint grease × 1 — Included in boot kit or use OEM specification
• Axle nut × 1 — Use OEM specification - single use only
• Split pin or cotter pin (if equipped) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal and wait 10 minutes for system capacitors to discharge
3. Loosen front wheel lug nuts while vehicle is on ground
4. With vehicle still on ground, have assistant apply brakes and break loose the axle nut (do not remove completely)
5. Raise vehicle on lift or jack stands rated for commercial EV weight, ensuring stability
6. Remove front wheel on side being serviced
7. Place wheel chocks behind rear wheels
8. Verify high voltage system is de-energized using Rivian service tool or multimeter per manufacturer protocol

Procedure

1. 1

   Remove axle nut and wheel components
   Fully remove the axle nut that was previously loosened. Remove brake caliper mounting bolts and secure caliper to suspension with mechanics wire without stressing brake hose. Remove brake rotor if it interferes with access. Mark the orientation of components for reassembly.
2. 2

   Disconnect outer tie rod and ball joint
   Remove the cotter pin and castle nut from outer tie rod end. Use ball joint separator to disconnect tie rod from knuckle. Remove lower ball joint pinch bolt or castle nut. Separate ball joint from knuckle using separator tool. Support lower control arm to prevent sudden drop.
3. 3

   Pull knuckle assembly outward
   Carefully pull the steering knuckle assembly outward away from the vehicle while supporting the axle shaft. This will expose the outer CV joint. You may need to rotate the hub to clear the axle splines. Use care not to damage ABS sensor or wiring.
4. 4

   Cut and remove damaged outer CV boot
   Using diagonal cutters, cut both clamps securing the outer CV boot (one at CV joint, one at axle shaft). Slide the damaged boot off the CV joint and down the axle shaft. Clean the area with shop towels to assess CV joint condition.
5. 5

   Inspect CV joint for damage
   Thoroughly inspect the outer CV joint for wear, scoring, pitting, or damaged ball bearings. Rotate the joint through full range of motion and check for rough spots or clicking. If any damage is found beyond surface contamination, the entire axle assembly must be replaced. Check axle shaft for scoring where boot seals.
6. 6

   Clean CV joint and axle shaft
   Remove all old grease from the CV joint using shop towels and suitable cleaner. Clean the axle shaft where the boot will seal. Use wire brush to remove any rust or debris from shaft. Ensure CV joint cage and ball bearings are completely clean and dry before repacking.
7. 7

   Pack CV joint with new grease
   Apply approximately half of the supplied CV joint grease directly into the CV joint housing, working it between all ball bearings and cage. Rotate joint while packing to ensure complete coverage. Reserve remaining grease for inside the boot.
8. 8

   Install new outer CV boot
   Slide the new outer CV boot onto the axle shaft from the inner side (may require partial disassembly or use split boot design if available). Position the small end of the boot in the groove on the axle shaft. Ensure boot is not twisted.
9. 9

   Secure small boot clamp
   Install the small boot clamp in the groove on the axle shaft. Using the CV boot clamp tool, tighten the clamp securely. Ensure the clamp is properly seated and boot material is not pinched. Bend locking tabs or crimp per clamp design.
10. 10

    Position boot and add remaining grease
    Pull the large end of the boot over the CV joint housing. Before seating completely, add the remaining grease into the boot cavity. Ensure total grease amount matches kit specifications (typically 4-6 oz total).
11. 11

    Seat boot and equalize pressure
    Seat the large end of the boot fully into the groove on the CV joint housing. Insert a small flat tool between boot and housing to equalize air pressure - boot should not be ballooning or collapsed. Remove tool and verify boot is properly seated in both grooves.
12. 12

    Install large boot clamp
    Install the large boot clamp in the groove on the CV joint housing. Using CV boot clamp tool, tighten clamp securely. Verify boot remains properly seated and is not twisted. Bend locking tabs or crimp per clamp design.
13. 13

    Reinstall axle into hub
    Push the knuckle assembly back toward the vehicle while guiding the axle shaft splines into the wheel hub. You may need to rotate the hub to align splines. Ensure axle is fully seated and hub moves freely on axle.
14. 14

    Reconnect suspension components
    Reconnect lower ball joint to knuckle and install pinch bolt or castle nut. Reconnect outer tie rod end to knuckle. Install new cotter pins where applicable. Verify all connections are secure and properly seated.
15. 15

    Install axle nut and wheel
    Install new axle nut (single use component) onto axle shaft and snug by hand. Reinstall brake rotor and caliper assembly. Install wheel and lug nuts. Lower vehicle until tire just contacts ground to prevent axle rotation, then torque axle nut to manufacturer specification (typically 175-200 ft-lbs for this class of vehicle, verify with service manual). Fully lower vehicle and torque wheel lug nuts in star pattern to specification.

Reassembly

1. Torque all fasteners to manufacturer specifications - consult Rivian service manual for exact values
2. Ensure all suspension components are properly aligned and seated
3. Verify brake caliper is securely mounted and brake hose is not twisted
4. Double-check that both CV boot clamps are properly secured and boot is not twisted
5. Reconnect 12V battery negative terminal

Verification

• Start vehicle and verify no warning lights related to ABS, traction control, or drivetrain systems
• Turn steering wheel full lock to lock while stationary and listen for unusual noises from CV joint
• Test drive vehicle at low speed and verify smooth operation with no clicking or popping from CV joint
• Perform full lock turns in both directions while driving slowly - CV joint should operate silently
• After test drive, raise vehicle and inspect new boot for leaks, proper seating, and secure clamps
• Verify no grease is being expelled from boot and clamps remain tight
• Check for proper wheel alignment if steering wheel is off-center

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