This procedure covers removal and replacement of the differential cover gasket on the front and/or rear differential of a 2024 Rivian EDV 500, including fluid drainage and refill.

Warnings

Tools required

Parts

• Front differential cover gasket × 1 — Use OEM specification
• Rear differential cover gasket × 1 — Use OEM specification
• Differential cover bolt set (if reusing bolts, inspect for thread damage) × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 3.5 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks at opposite end from differential being serviced
3. Lift vehicle using manufacturer-specified lift points and secure on jack stands
4. Remove wheels if necessary for access to differential covers (rear differential typically accessible without wheel removal)
5. Clean exterior of differential housing and cover area with degreaser to prevent contamination during service
6. Verify which differential(s) require gasket replacement and gather appropriate parts

Procedure

1. 1

   Position drain pan and remove fill plug
   Position drain pan under the differential cover to be serviced. Locate the fill plug on the differential housing (typically on the front or side of the housing). Use appropriate metric socket to loosen and remove the fill plug first to ensure you can refill the differential after service. Inspect fill plug and threads for damage.
2. 2

   Remove differential cover bolts
   Identify all differential cover bolts (typically 10-14 bolts depending on front or rear differential). Begin loosening bolts in a crisscross pattern, starting from the center and working outward. Leave two bolts at opposite corners partially threaded to prevent cover from dropping. Ensure drain pan is positioned to catch fluid as cover loosens.
3. 3

   Drain differential fluid
   Once most bolts are removed, carefully loosen one of the remaining bolts while supporting the cover. Allow the cover to tilt slightly to let gear oil drain into the pan. Once flow slows, remove the final bolts and carefully remove the cover. Be prepared for additional fluid to drain. Allow differential to drain completely for at least 10 minutes.
4. 4

   Inspect internal components
   With cover removed, visually inspect the ring gear, pinion gear, and bearings for abnormal wear, metal shavings, or damage. Check the magnetic drain plug (if equipped) for excessive metal debris. Small amounts of fine metallic paste are normal, but large chunks or excessive material indicate potential component failure requiring further diagnosis.
5. 5

   Clean differential cover mating surface
   Remove old gasket material from the differential housing mating surface using a plastic or brass gasket scraper. Do not use steel scrapers that could gouge the aluminum housing. Clean the surface thoroughly with brake cleaner and shop rags. Ensure no gasket material, dirt, or debris remains on the mating surface. The surface must be completely clean and dry for proper gasket sealing.
6. 6

   Clean differential cover
   Clean the differential cover itself, removing all old gasket material from the cover mating surface. Clean the interior of the cover and inspect the magnetic drain area. Use brake cleaner to remove all oil residue from both mating surfaces. Inspect cover for warping or damage that could prevent proper sealing.
7. 7

   Install new gasket
   Position the new differential cover gasket on the housing mating surface or on the cover (per gasket design). Some gaskets have an adhesive backing; others may require a thin bead of RTV sealant on one side only (consult Rivian service procedures). Ensure all bolt holes align properly and gasket is seated evenly around the entire perimeter.
8. 8

   Install differential cover
   Carefully position the differential cover onto the housing, aligning the gasket and all bolt holes. Start all cover bolts by hand to ensure proper threading and alignment. Do not force any bolts. Once all bolts are hand-started, ensure the cover is seated evenly against the gasket.
9. 9

   Torque differential cover bolts
   Note: Manufacturer torque specifications are not available in the database. Consult Rivian service information for specific torque values. Tighten cover bolts in a crisscross pattern, working from the center outward. Use multiple passes, gradually increasing torque to final specification to ensure even gasket compression and prevent warping or leaks.
10. 10

    Refill differential with gear oil
    Using a fluid pump or funnel with extension hose, refill the differential through the fill hole with 75W-90 GL-5 gear oil. Front differential requires 1.5 quarts; rear differential requires 2.0 quarts. Fill slowly to prevent air pockets. Fill until oil begins to drip from the fill hole, indicating proper level. Allow a few minutes for oil to settle and top off if necessary.
11. 11

    Install fill plug and verify
    Clean the fill plug threads and inspect the sealing washer (replace if damaged or if specified by manufacturer). Install the fill plug and tighten to specification (consult Rivian service information for torque value). Wipe down the differential housing to remove any spilled oil. Inspect the cover for any signs of immediate leakage around the gasket.
12. 12

    Repeat for second differential if necessary
    If servicing both front and rear differentials, repeat steps 1-11 for the second differential. Ensure proper fluid quantities for each differential (1.5 qt front, 2.0 qt rear). Maintain cleanliness throughout the procedure to prevent contamination.

Reassembly

1. Reinstall wheels if removed and torque lug nuts to manufacturer specification
2. Lower vehicle from jack stands or lift
3. Dispose of used gear oil properly at a recycling facility; do not pour down drains

Verification

• After repairs, test drive vehicle for 10-15 minutes, making several turns in both directions to circulate gear oil and verify proper differential operation
• Re-lift vehicle and inspect differential cover gasket area for any signs of leakage
• Check differential fill plug for seepage and retighten if necessary
• Listen for any abnormal noises from differentials during test drive (whining, grinding, or clunking may indicate installation issues or pre-existing component damage)
• Verify proper AWD operation by monitoring vehicle systems and ensuring no drivetrain warning lights appear

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