This procedure covers the complete drain and refill of the front differential fluid on the 2024 Rivian EDV 500 electric delivery van with dual motor all-wheel drive.

Warnings

Tools required

Parts

• Front differential drain plug gasket/washer × 1 — Use OEM specification
• Front differential fill plug gasket/washer × 1 — 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. Verify 12V battery is in good condition (needed for electronic systems during service)
4. Allow differential to cool to ambient temperature if recently driven
5. Raise vehicle on lift or jack stands ensuring it is level for accurate fluid fill
6. Remove front skid plate or undertray panels to access front differential housing
7. Clean the area around the differential drain and fill plugs to prevent contamination

Procedure

1. 1

   Locate and identify service points
   The front differential on the EDV 500 is integrated with the front drive unit. Locate the fill plug on the upper side of the differential housing and the drain plug on the lower section. Verify both plugs are accessible and identify the plug size needed. Take note of any protective covers or heat shields that may need removal.
2. 2

   Break loose fill plug first
   Before draining, always loosen the fill plug first to ensure you can refill the differential. Using the appropriate socket, break the fill plug loose by turning counterclockwise approximately 1/4 turn. If the fill plug is seized and cannot be removed, do not proceed with draining. Leave the fill plug loose but in place.
3. 3

   Position drain pan and remove drain plug
   Position a drain pan with at least 3-quart capacity directly beneath the differential drain plug. Using the appropriate socket, slowly remove the drain plug completely, turning counterclockwise. Be prepared for fluid to flow immediately. Allow the drain plug and washer to fall into the drain pan, then retrieve with a magnetic pickup tool.
4. 4

   Drain differential completely
   Allow the differential fluid to drain completely, which may take 10-15 minutes. The fluid should appear amber to dark brown. Inspect the drained fluid for metal particles, glitter, or debris which may indicate internal wear. Minor fine particles on the magnetic drain plug are normal, but large chunks or excessive material indicate further inspection is needed.
5. 5

   Inspect and clean drain plug
   Inspect the drain plug for damage to the threads or magnetic tip. Clean the magnetic portion of any metallic debris using a shop rag. Inspect the drain plug sealing surface for scratches or damage. Discard the old crush washer or gasket and prepare the new one.
6. 6

   Install drain plug with new gasket
   Install the new drain plug gasket onto the drain plug. Thread the drain plug into the differential housing by hand to ensure proper thread engagement and prevent cross-threading. Once hand-tight, use a torque wrench to tighten the drain plug to the manufacturer's specification. Note: Torque specification not available in database - consult Rivian service manual or tighten to 25-35 ft-lbs as typical for differential drain plugs of this size.
7. 7

   Remove fill plug completely
   Fully remove the fill plug that was previously loosened, turning counterclockwise. Remove and inspect the fill plug gasket. Clean any debris from the fill plug hole opening using a clean shop rag. Inspect the threads in the fill hole for damage.
8. 8

   Fill differential with new gear oil
   Using a fluid transfer pump or fill bottle with hose extension, begin filling the differential with fresh 75W-90 GL-5 gear oil. The fill hole is typically positioned at the proper level - fill until fluid begins to seep out of the fill hole. The front differential requires approximately 1.5 quarts. Fill slowly to allow air to escape and prevent overfilling.
9. 9

   Verify proper fluid level
   Proper level is achieved when fluid reaches the bottom of the fill plug hole and begins to drip out slowly. With the vehicle level, fluid should be just at the edge of the fill hole opening. If fluid does not appear, add additional fluid in small increments until it does. Allow 2-3 minutes for fluid to settle and recheck level.
10. 10

    Install fill plug with new gasket
    Install the new fill plug gasket onto the fill plug. Wipe away any excess fluid from around the fill hole area. Thread the fill plug in by hand to start, ensuring proper thread engagement. Once hand-tight, use a torque wrench to tighten the fill plug to manufacturer's specification. Note: Torque specification not available in database - consult Rivian service manual or tighten to 25-35 ft-lbs as typical.
11. 11

    Clean differential housing exterior
    Using shop rags, clean any spilled gear oil from the differential housing, suspension components, and surrounding areas. Gear oil on rubber components can cause degradation over time. Ensure the area is clean so any future leaks can be easily identified.
12. 12

    Reinstall undertray and lower vehicle
    Reinstall any skid plates, undertrays, or protective covers that were removed for access. Ensure all fasteners are properly secured. Carefully lower the vehicle from the lift or jack stands to the ground.

Reassembly

1. Double-check that both drain and fill plugs are properly torqued and not seeping fluid
2. Verify all undertray panels and skid plates are reinstalled and secured
3. Dispose of used gear oil properly at a recycling center - do not pour down drains
4. Record the service date and mileage for maintenance tracking

Verification

• Start the vehicle and allow it to run for 1-2 minutes to circulate the new fluid through the front drive unit
• Test drive the vehicle at low speed for 5-10 minutes, making several turns in both directions to fully distribute the new fluid
• After test drive, re-raise the vehicle and inspect both drain and fill plugs for any signs of leakage
• Check the area beneath the differential for drips after the vehicle has sat for 15-30 minutes
• If available, use Rivian diagnostic scanner to verify no front drive unit fault codes are present
• Listen for any abnormal noises from the front differential during operation - properly filled differential should operate silently

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