This procedure covers the replacement of the differential pinion seal on a 2024 Rivian EDV 500 Dual Motor AWD, including driveshaft removal, seal replacement, and differential fluid refill.

Warnings

Tools required

Parts

• Differential pinion seal (front or rear as applicable) × 1 — Use OEM Rivian specification
• Pinion nut (recommended replacement) × 1 — Use OEM specification
• Driveshaft flange bolts/nuts (if applicable) × 1 — Use OEM specification
• Drain plug crush washer × 1 — Use OEM specification
• Fill plug crush washer × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil (front differential) — 1.5 qt
• 75W-90 GL-5 Gear Oil (rear differential) — 2 qt

Preparation

1. Verify which differential (front or rear) requires pinion seal replacement
2. Park vehicle on level ground and apply parking brake
3. Disable high-voltage system per Rivian service procedures and install safety lock-out device
4. Raise vehicle on appropriate lift or jack stands rated for EV weight
5. Remove wheel(s) on affected axle for improved access if necessary
6. Place drain pan under differential
7. Allow differential to cool to ambient temperature if vehicle was recently driven
8. Clean exterior of differential housing and surrounding area to prevent contamination

Procedure

1. 1

   Mark pinion flange position and measure preload
   Before disassembly, use a paint marker or center punch to mark the relationship between the pinion shaft and pinion flange for reassembly reference. Using an inch-pound torque wrench on the pinion nut, measure and record the rotational torque required to turn the pinion (pinion bearing preload). This is critical for proper reassembly. Typical preload is 15-25 in-lbs for used bearings. Rotate the pinion several times and take multiple readings to get an accurate average.
2. 2

   Drain differential fluid
   Locate the differential drain plug on the bottom of the differential housing. Position drain pan underneath. Remove drain plug and allow fluid to fully drain (approximately 1.5 quarts for front differential, 2.0 quarts for rear differential). Inspect drained fluid for metal particles or contamination. Remove fill plug to allow complete drainage and venting.
3. 3

   Remove driveshaft from pinion flange
   Locate the driveshaft connection to the pinion flange. Mark the driveshaft flange position relative to the pinion flange for proper reinstallation phasing. Remove the driveshaft mounting bolts or nuts. Support the driveshaft and carefully separate it from the pinion flange. Secure driveshaft out of the way using wire or a strap. Do not allow driveshaft to hang unsupported as this can damage CV joints or center bearing.
4. 4

   Remove pinion nut
   Install the pinion flange holding tool to prevent the flange from rotating. Using a breaker bar and appropriate socket, remove the pinion nut. This nut is typically torqued to very high specification and may require significant force. Note: This nut should be replaced during reassembly as it is often a prevailing torque (self-locking) type.
5. 5

   Remove pinion flange
   With the pinion nut removed, carefully pull the pinion flange from the pinion shaft. If the flange is tight, use a suitable puller to avoid damaging the pinion shaft threads. Do not use heat or excessive force. Remove the flange and set aside. Inspect the pinion shaft sealing surface for wear, grooves, or damage. If the shaft shows wear, the differential may require more extensive service.
6. 6

   Remove old pinion seal
   Using a seal puller or carefully positioned pry bar, remove the old pinion seal from the differential housing. Work carefully to avoid damaging the seal bore in the housing. Inspect the seal bore for scratches, burrs, or damage. Clean the seal bore thoroughly with a lint-free cloth and appropriate solvent. Any imperfections in the seal bore must be addressed or the new seal will leak.
7. 7

   Install new pinion seal
   Lightly coat the outer diameter of the new pinion seal with gear oil. Apply a thin coat of gear oil to the seal lip. Using an appropriately sized seal driver that contacts only the outer edge of the seal (never the center), carefully drive the seal squarely into the bore until it is fully seated and flush with the housing. Verify the seal is seated evenly around its entire circumference. Apply a light coat of gear oil to the sealing lip.
8. 8

   Reinstall pinion flange
   Apply a thin coat of gear oil to the pinion shaft where it contacts the seal. Carefully slide the pinion flange onto the pinion shaft, aligning with the reference marks made during disassembly. Ensure the flange is fully seated. Install the new pinion nut (or clean and inspect the old nut if reusing, though replacement is recommended).
9. 9

   Torque pinion nut and set bearing preload
   Using the pinion flange holding tool, begin tightening the pinion nut gradually. Tighten in incremental steps while periodically checking rotational torque with an inch-pound torque wrench. The goal is to achieve the same pinion bearing preload recorded during disassembly (typically 15-25 in-lbs for used bearings). If installing new bearings, preload would be higher (typically 20-30 in-lbs). Once proper preload is achieved, the pinion nut is at correct torque. Note: Without manufacturer torque specifications, achieving proper preload is critical. If preload is exceeded, the collapsible spacer (if equipped) is crushed and differential disassembly is required.
10. 10

    Reinstall driveshaft
    Position the driveshaft to the pinion flange, aligning the reference marks made during disassembly. Install driveshaft mounting bolts or nuts and tighten in a cross-pattern. Support the driveshaft during installation to prevent strain on components. Verify all fasteners are properly installed and secured.
11. 11

    Refill differential
    Install new drain plug crush washer and reinstall drain plug, tightening securely. Using a fluid pump and appropriate 75W-90 GL-5 gear oil, fill the differential through the fill hole. Fill until fluid begins to drip from the fill hole (front differential: approximately 1.5 quarts; rear differential: approximately 2.0 quarts). Install new fill plug crush washer and reinstall fill plug, tightening securely.
12. 12

    Final inspection and system check
    Wipe down all surfaces and inspect for any fluid leaks around the pinion seal area. Rotate the pinion by hand several complete revolutions to ensure smooth operation with no binding. Check that all fasteners are properly torqued. Remove jack stands and lower vehicle. If Rivian diagnostic software is available, clear any fault codes and verify drive system functionality.

Reassembly

1. Reinstall wheels if removed and torque lug nuts to specification
2. Re-enable high-voltage system per Rivian service procedures
3. Verify parking brake releases properly
4. Clean any spilled gear oil from chassis, suspension, and floor

Verification

• Start vehicle and verify no warning lights related to drivetrain are illuminated
• Test drive vehicle in a safe area at low speed, verifying smooth operation in both forward and reverse
• Listen for any abnormal noises from differential area during acceleration and deceleration
• After initial test drive (5-10 minutes), re-inspect pinion seal area for any signs of leakage
• After 50-100 miles of driving, recheck differential fluid level and top off if necessary
• Monitor for leaks over the next several days of operation

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