This procedure covers the removal and replacement of the front differential assembly on the 2024 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• Front differential assembly × 1 — Use OEM specification
• Differential mounting bolts × 1 — Use OEM specification
• Axle shaft seals × 2 — Use OEM specification
• Differential gasket or RTV sealant × 1 — Use OEM specification
• Drain plug crush washer × 1 — Use OEM specification
• Fill plug O-ring × 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. Disconnect 12V auxiliary battery negative terminal
4. Verify high voltage system is de-energized per manufacturer service procedures
5. Raise vehicle on lift or jack stands to working height
6. Remove both front wheels
7. Remove front skid plate or underbody panels for access to differential
8. Allow differential to cool if vehicle was recently operated
9. Clean area around differential to prevent contamination during service

Procedure

1. 1

   Drain differential fluid
   Position drain pan beneath the front differential. Remove the drain plug from the bottom of the differential housing and allow the 75W-90 gear oil to drain completely. Inspect the drained fluid for metal particles or contamination that may indicate internal damage. Remove the fill plug to aid in draining.
2. 2

   Disconnect front axle shafts
   Mark the position of both front axle shafts relative to the differential output flanges for proper reinstallation. Remove the bolts securing each axle shaft to the differential output flanges. Support the axle shafts and carefully separate them from the differential, being careful not to damage the CV boots. Secure axle shafts out of the way using wire or bungee cords.
3. 3

   Disconnect electrical connections
   Locate and photograph all electrical connectors on the front differential assembly. The EDV 500 front differential may have speed sensors, temperature sensors, or actuator connections. Carefully disconnect all electrical connectors, releasing any locking tabs. Label connectors if necessary for reassembly.
4. 4

   Disconnect propeller shaft or input shaft
   Identify the connection between the front motor/drive unit and the differential input. Mark the orientation of any flanges or yokes for proper alignment during reassembly. Remove the bolts or fasteners securing the input connection. Support the propeller shaft or drive component to prevent it from hanging unsupported.
5. 5

   Support the differential
   Position a transmission jack or suitable differential support device beneath the front differential assembly. Adjust the support to just contact the differential housing, taking care not to apply upward pressure yet. Secure the differential to the support using safety straps or chains to prevent it from falling during removal.
6. 6

   Remove differential mounting bolts
   Locate all differential mounting bolts securing the assembly to the front subframe or crossmember. There are typically 4-6 mounting points. Support the weight of the differential with the transmission jack. Remove the mounting bolts in a cross pattern, leaving one bolt partially threaded on each side until the others are removed. Carefully remove the final bolts while controlling the differential position with the jack.
7. 7

   Lower and remove differential
   Slowly and carefully lower the transmission jack, guiding the front differential assembly down and away from the vehicle. Watch for any remaining connections, hoses, or wiring that may have been missed. Once clear of the vehicle, move the differential to a clean work surface for inspection or replacement.
8. 8

   Inspect mounting locations
   With the differential removed, inspect all mounting points on the subframe for damage, cracks, or excessive wear. Check the mounting bolt holes for elongation or thread damage. Inspect the area for any fluid leaks from other components that may have been hidden by the differential. Clean all mounting surfaces thoroughly.
9. 9

   Prepare new or rebuilt differential
   If installing a new or rebuilt differential, verify it matches the original unit specifications and part number. Check that all mounting points align correctly. Install new seals at the axle shaft outputs. Verify the differential contains the correct amount of 75W-90 GL-5 gear oil (1.5 quarts total) or prepare to fill after installation.
10. 10

    Position and raise differential
    Place the replacement differential on the transmission jack and secure it with safety straps. Apply a thin coat of anti-seize to the mounting bolt threads (unless they are thread-locking type). Carefully raise the differential into position, aligning the mounting holes with the subframe. Guide the input shaft and output flanges into their proper positions.
11. 11

    Install mounting bolts
    Thread all differential mounting bolts by hand to ensure proper alignment before tightening any of them. Once all bolts are started, tighten them in a cross pattern to ensure even seating. Follow manufacturer torque specifications for all mounting bolts. Verify the differential is seated properly against all mounting surfaces with no gaps.
12. 12

    Reconnect input shaft and electrical connections
    Align the propeller shaft or input connection to the differential using the alignment marks made during disassembly. Install and torque the input shaft fasteners to specification. Reconnect all electrical connectors to their proper locations, ensuring all locking tabs engage fully. Route wiring as originally installed to prevent chafing or interference.
13. 13

    Reconnect axle shafts
    Carefully guide both front axle shafts back onto the differential output flanges, aligning them with the marks made during disassembly. Install new axle shaft bolts if specified by the manufacturer. Tighten axle shaft bolts in a star pattern to specification. Verify CV boots were not damaged during installation.
14. 14

    Fill differential with gear oil
    If the differential was not pre-filled, use a fluid pump to fill the front differential with 1.5 quarts of 75W-90 GL-5 gear oil through the fill port. Fill until fluid begins to seep from the fill hole, indicating proper level. Install a new O-ring on the fill plug and install the plug to specification. Install the drain plug with a new crush washer.
15. 15

    Final inspection and reinstallation
    Perform a final visual inspection of all connections, bolts, and components. Verify no tools or parts were left in the work area. Reinstall the front skid plate or underbody panels. Install both front wheels and torque lug nuts to specification. Lower the vehicle to the ground. Reconnect the 12V auxiliary battery negative terminal.

Reassembly

1. Tighten all fasteners to manufacturer specifications using a calibrated torque wrench
2. Ensure all electrical connectors are fully seated with locking tabs engaged
3. Route all wiring and hoses as originally installed to prevent interference
4. Double-check that all mounting bolts are installed and properly torqued
5. Verify differential fluid level is correct at 1.5 quarts for the front differential

Verification

• Start the vehicle and verify no warning lights appear on the instrument cluster related to the drivetrain
• Perform a test drive at low speed in a safe area, checking for unusual noises, vibrations, or handling issues
• Test both acceleration and regenerative braking to verify proper front motor/differential operation
• Re-check differential fluid level after test drive and top off if necessary
• Inspect for any fluid leaks around the differential housing, drain plug, fill plug, and axle shaft seals
• Verify all warning lights remain off and the AWD system functions properly
• Perform a final torque check on all accessible fasteners after the test drive

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