This procedure covers the replacement of differential fluid in both front and rear differentials on the 2024 Rivian EDV 500 dual motor electric delivery van.

Warnings

Tools required

Parts

• Front differential drain plug washer/gasket × 1 — Use OEM specification
• Front differential fill plug washer/gasket × 1 — Use OEM specification
• 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 (Front Differential) — 1.5 qt
• 75W-90 GL-5 Gear Oil (Rear Differential) — 2 qt

Preparation

1. Drive vehicle for 5-10 minutes to warm differential fluid, then allow to cool for 30 minutes
2. Park vehicle on level surface and engage parking brake
3. Place wheel chocks behind wheels that will remain on ground
4. Lift vehicle using manufacturer-specified lift points and secure on jack stands if not using a commercial lift
5. Verify vehicle is stable and secure before working underneath
6. Locate front and rear differential housings integrated into motor assemblies
7. Clean area around drain and fill plugs on both differentials using wire brush and shop towels

Procedure

1. 1

   Access front differential service plugs
   From under the vehicle, locate the front electric motor assembly between the front wheels. Identify the differential fill plug (upper position, typically on the side of the housing) and drain plug (lower position at the bottom of the housing). Clean both plugs and surrounding area thoroughly to prevent contamination.
2. 2

   Remove front differential fill plug first
   Using the appropriate hex socket or wrench, loosen and remove the fill plug before draining. This ensures the differential can be refilled after draining. If the fill plug is seized or damaged, do not proceed with draining until the fill plug issue is resolved. Inspect the fill plug washer/gasket and set aside with new replacement.
3. 3

   Drain front differential fluid
   Position drain pan under the front differential drain plug. Remove the drain plug slowly and allow fluid to drain completely. This may take 10-15 minutes for thorough drainage. Inspect drained fluid for metal particles or contamination. Excessive metallic debris may indicate internal wear requiring further inspection.
4. 4

   Clean and reinstall front differential drain plug
   Clean the drain plug threads and magnetic tip (if equipped) with shop towels. Clean the drain hole threads with a clean towel. Install a new drain plug washer/gasket. Thread the drain plug in by hand first to prevent cross-threading, then tighten to manufacturer specification. Without a torque specification provided, tighten firmly to approximately 25-30 ft-lb, being careful not to strip aluminum housing threads.
5. 5

   Refill front differential
   Using a fluid transfer pump or squeeze bottle, inject 1.5 quarts of 75W-90 GL-5 gear oil through the fill hole. Fill until fluid begins to seep out of the fill hole, indicating proper level. Allow excess to drain back, then wait 2-3 minutes for fluid to settle before verifying level is at the bottom of the fill hole.
6. 6

   Reinstall front differential fill plug
   Install new fill plug washer/gasket onto the fill plug. Thread the fill plug in by hand to prevent cross-threading. Tighten to manufacturer specification or approximately 25-30 ft-lb if specification is not available. Wipe away any excess oil from the housing.
7. 7

   Access rear differential service plugs
   Move to the rear of the vehicle and locate the rear electric motor assembly between the rear wheels. The rear differential is larger due to higher torque output. Identify the fill plug (upper/side position) and drain plug (lower position). Clean both plugs and surrounding area thoroughly.
8. 8

   Remove rear differential fill plug first
   Remove the rear differential fill plug before draining, using the same procedure as the front. Verify the fill plug can be removed and is not seized. Inspect the fill plug washer/gasket and prepare new replacement. Keep fill and drain plugs from front and rear differentials separated as they may be different sizes.
9. 9

   Drain rear differential fluid
   Position drain pan under the rear differential drain plug. Remove the drain plug and allow fluid to drain completely. The rear differential holds 2.0 quarts and may take 15-20 minutes to drain thoroughly. Inspect drained fluid for contamination or excessive metal particles.
10. 10

    Clean and reinstall rear differential drain plug
    Clean the drain plug, magnetic tip if equipped, and drain hole threads. Install new drain plug washer/gasket. Hand-thread the drain plug first, then tighten to specification or approximately 25-30 ft-lb, being careful with aluminum housing threads.
11. 11

    Refill rear differential
    Using a fluid transfer pump, inject 2.0 quarts of 75W-90 GL-5 gear oil through the rear differential fill hole. Fill until fluid reaches the bottom of the fill hole and begins to seep out. Allow to settle for 2-3 minutes and verify proper level.
12. 12

    Reinstall rear differential fill plug
    Install new fill plug washer/gasket and thread the fill plug in by hand. Tighten to specification or approximately 25-30 ft-lb. Wipe away excess oil from the housing. Perform final inspection of both front and rear differentials to ensure no leaks are present around drain or fill plugs.

Reassembly

1. Perform final inspection of all plug installations on both differentials
2. Verify no tools or materials are left under the vehicle
3. Carefully lower vehicle from lift or jack stands
4. Remove wheel chocks
5. Dispose of used gear oil at an appropriate recycling facility according to local regulations

Verification

• Start vehicle and allow drive system to initialize
• Drive vehicle forward and reverse slowly for several feet to circulate new fluid
• Re-lift vehicle and inspect both differentials for any signs of leakage around drain and fill plugs
• Test drive vehicle at various speeds and verify normal operation with no unusual noises from differentials
• After 50-100 miles of driving, perform visual inspection under vehicle to confirm no leaks have developed

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