This procedure drains and refills the rear differential gear oil on the 2024 Rivian EDV 500 dual motor AWD electric delivery van to maintain proper lubrication of the rear drive unit.

Warnings

Tools required

Parts

• Rear differential drain plug washer/gasket × 1 — Use OEM specification
• Rear differential fill plug washer/gasket × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks at front wheels
3. Using the vehicle's touchscreen interface, navigate to Service Mode and enable 'High Voltage Isolation' to disconnect the high voltage battery system
4. Raise vehicle on lift or use proper jack points and secure with jack stands rated for EDV 500 weight (check service manual for proper lift points)
5. Allow rear differential to cool to safe handling temperature if vehicle was recently driven
6. Locate the rear drive unit assembly underneath the vehicle at the rear axle
7. Clean the area around the differential fill and drain plugs with wire brush to prevent contamination

Procedure

1. 1

   Locate service plugs
   Identify the rear differential fill plug (typically located on the side or upper portion of the drive unit housing) and drain plug (located at the bottom of the housing). Reference the service manual diagram if needed to confirm plug locations on the Rivian rear drive unit.
2. 2

   Remove fill plug first
   Using the appropriate socket, carefully loosen and remove the fill plug first. This relieves any internal pressure and ensures you can refill the differential after draining. If the fill plug is seized or cannot be removed, do not proceed with draining.
   ⚠Always remove the fill plug before the drain plug to ensure the differential can be refilled. A seized fill plug with drained fluid will require drive unit replacement or professional extraction.
3. 3

   Position drain pan
   Place the drain pan directly beneath the drain plug with adequate capacity to catch approximately 2 quarts of gear oil. Position the pan slightly forward to account for initial fluid stream angle.
4. 4

   Remove drain plug
   Slowly loosen the drain plug using the appropriate socket. Remove the drain plug completely and allow the gear oil to drain fully into the pan. This may take 5-10 minutes for complete drainage. Inspect the drain plug for metal shavings or debris on the magnetic tip (if equipped).
5. 5

   Inspect drained fluid
   Examine the drained gear oil for excessive metal particles, discoloration, or contamination. Normal gear oil will have fine metallic particles on the magnetic drain plug. Excessive chunks or glitter may indicate internal wear requiring further inspection.
6. 6

   Clean and inspect drain plug
   Wipe the drain plug clean with shop towels. Clean the magnetic tip thoroughly if equipped. Inspect the drain plug threads for damage. Remove and discard the old drain plug washer or gasket.
7. 7

   Install new drain plug washer
   Install a new drain plug washer or gasket onto the drain plug. Ensure the washer is properly seated against the plug shoulder and oriented correctly per manufacturer design.
8. 8

   Reinstall drain plug
   Thread the drain plug by hand into the differential housing to prevent cross-threading. Once hand-tight, use a torque wrench to tighten to the manufacturer's specified torque value. Note: Torque specification not available in database - consult Rivian service documentation for proper torque value.
   ⚠Do not over-tighten the drain plug as this may strip the aluminum housing threads or damage the sealing surface.
9. 9

   Fill rear differential
   Using a fluid transfer pump or squeeze bottle with appropriate nozzle, begin filling the differential through the fill plug opening with new 75W-90 GL-5 gear oil. Fill slowly to allow air to escape and prevent overflow. Continue filling until fluid begins to drip from the fill plug opening, indicating proper level (approximately 2.0 quarts).
10. 10

    Install fill plug
    Install a new fill plug washer or gasket onto the fill plug. Wipe excess oil from around the fill opening. Thread the fill plug by hand, then torque to manufacturer specification using a torque wrench. Note: Torque specification not available in database - consult Rivian service documentation.
11. 11

    Clean work area
    Wipe down the rear drive unit housing to remove any spilled gear oil. Inspect for leaks around both the drain and fill plugs. Clean any drips from surrounding components.
12. 12

    Lower vehicle and exit Service Mode
    Carefully lower the vehicle from the lift or remove jack stands and lower from jack. Remove wheel chocks. Using the vehicle touchscreen, exit Service Mode and re-enable the high voltage battery system.

Reassembly

1. Ensure both drain and fill plugs are torqued to specification with new washers installed
2. Verify no gear oil leaks are present around plug locations
3. Properly dispose of used gear oil at an approved recycling facility

Verification

• Start the vehicle and verify normal operation with no warning lights on the instrument cluster
• Test drive the vehicle in a safe area, making turns in both directions to distribute the new gear oil
• After test drive, re-inspect the drain and fill plugs for any signs of leakage
• Monitor for any unusual noises from the rear drive unit during initial operation
• Verify proper fluid level by briefly removing fill plug - fluid should be at the bottom edge of the fill plug opening

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