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

Warnings

Tools required

Parts

• Rear differential assembly × 1 — Use OEM specification
• Differential mounting bolts/hardware kit × 1 — Use OEM specification
• Axle shaft seals (left and right) × 2 — Use OEM specification
• Differential drain plug washer × 1 — Use OEM specification
• Differential fill plug washer × 1 — Use OEM specification
• Propeller shaft coupling bolts × 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. Use Rivian diagnostic tool to disable high-voltage system and enter service mode
3. Disconnect 12V battery negative terminal
4. Wait minimum 5 minutes for high-voltage capacitor discharge
5. Raise vehicle on lift or secure jack stands under manufacturer-specified lift points
6. Remove both rear wheels
7. Place wheel chocks in front of front wheels
8. Have replacement differential assembly inspected and ready for installation
9. Verify replacement differential matches VIN-specific configuration

Procedure

1. 1

   Drain rear differential fluid
   Position drain pan under rear differential. Locate and remove the differential drain plug on the bottom of the housing. Allow all gear oil to drain completely (approximately 2 quarts). Remove fill plug to speed drainage. Inspect drained fluid for metal particles or contamination that may indicate additional damage.
2. 2

   Disconnect rear propeller shaft
   Mark the alignment of the propeller shaft coupling to the differential input flange for proper reinstallation. Remove the coupling bolts connecting the propeller shaft to the differential. Support the propeller shaft and secure it out of the way using mechanics wire or zip ties to prevent damage to the CV joint or boot.
3. 3

   Disconnect electrical connections
   Locate and disconnect all electrical connectors from the rear motor/differential assembly. This includes motor power cables, temperature sensors, speed sensors, and position sensors. Label each connector for proper reinstallation. Secure cables away from work area to prevent damage.
4. 4

   Remove rear axle shafts
   Remove the axle shaft retaining bolts/clips at the differential housing on both sides. Using an axle puller or by carefully prying, separate the axle shafts from the differential side gears. Support the axle shafts and secure them to the suspension or chassis to prevent them from hanging on CV joints. Cover the differential openings with clean shop towels to prevent contamination.
5. 5

   Disconnect coolant lines (if equipped)
   The rear motor may have integrated cooling lines. Place a drain pan underneath and disconnect coolant hoses from the motor/differential housing. Cap or plug all open coolant lines immediately to prevent fluid loss and contamination. Note the routing of coolant lines for proper reinstallation.
6. 6

   Support differential assembly
   Position a transmission jack or differential jack under the center of the differential housing. Adjust the jack to make light contact with the differential, ensuring it is balanced and secure. Use safety straps or chains to secure the assembly to the jack to prevent it from falling during removal.
7. 7

   Remove differential mounting bolts
   Locate all differential mounting bolts connecting the assembly to the rear subframe or chassis. There are typically 4-6 mounting points. Remove the mounting bolts while supporting the differential with the jack. Keep track of bolt locations as they may be different lengths. Check for any additional brackets or support members that need to be removed.
8. 8

   Remove differential assembly
   With all connections and mounting bolts removed, carefully lower the differential assembly using the jack. Guide the assembly clear of the vehicle chassis, being careful not to damage brake lines, suspension components, or body panels. Have an assistant help guide the assembly if needed. Once clear, move the assembly to a clean work area.
9. 9

   Prepare replacement differential
   Inspect the replacement differential assembly for any shipping damage or missing components. Verify all mounting points are clean and free of corrosion. Install new axle shaft seals into the differential housing, ensuring they are properly seated and oriented. Apply a light coat of gear oil to the seal lips. Verify the differential is pre-filled with gear oil or prepare to fill after installation.
10. 10

    Install replacement differential
    Mount the replacement differential assembly on the transmission jack and secure with straps. Carefully raise the assembly into position, aligning mounting points with the subframe or chassis. Thread in mounting bolts by hand to prevent cross-threading. Ensure no wires, hoses, or components are pinched. Once all bolts are started, tighten in a star pattern to ensure even seating.
11. 11

    Reconnect coolant lines and electrical connections
    Reconnect all coolant lines to the motor/differential housing, ensuring proper routing and no kinks. Tighten hose clamps securely. Reconnect all electrical connectors in their original positions, ensuring they click or lock into place. Verify no pins are bent or damaged. Route all wiring away from hot or moving components.
12. 12

    Install rear axle shafts
    Clean the axle shaft splines and apply a thin coat of gear oil. Carefully align and insert each axle shaft into the differential side gears, ensuring they are fully seated. Install retaining bolts or clips and tighten securely. Verify axle shafts have minimal in-and-out play, indicating proper seating.
13. 13

    Reconnect propeller shaft
    Remove support from the propeller shaft. Align the propeller shaft coupling with the differential input flange using the alignment marks made during disassembly. Install new coupling bolts and tighten in a star pattern to ensure even clamping force. Verify the shaft rotates smoothly by hand without binding.
14. 14

    Fill differential with gear oil
    Using a fluid pump, fill the rear differential through the fill plug opening with 2.0 quarts of 75W-90 GL-5 gear oil. Fill until oil begins to seep from the fill hole, indicating proper level. Install a new fill plug washer and install the fill plug, tightening securely. Install a new drain plug washer on the drain plug and tighten securely.
15. 15

    Perform system checks and initialization
    Reinstall rear wheels and lower vehicle to ground. Reconnect 12V battery. Use Rivian diagnostic tool to clear any fault codes and perform rear differential initialization/calibration procedures. This may include motor position learning and torque vectoring calibration. Verify all systems show ready status before test driving.

Reassembly

1. Ensure all mounting bolts are tightened to manufacturer specifications once available
2. Verify all electrical connectors are fully seated and locked
3. Check coolant level and top off if necessary after reconnecting lines
4. Inspect area around differential for any forgotten tools or loose fasteners
5. Torque wheel lug nuts to manufacturer specification in star pattern

Verification

• Start vehicle and verify no warning lights or error messages on dashboard
• Use diagnostic tool to verify rear differential is communicating properly and showing correct temperature readings
• Perform a slow test drive and verify smooth operation without noise, vibration, or harshness
• Test all-wheel-drive engagement in a safe area to confirm power delivery to rear wheels
• After test drive, inspect differential and all connections for any signs of leaks
• Check differential fluid level again after test drive and top off if needed
• Clear any stored fault codes and verify none return after test drive
• Document differential serial number and installation date for service records

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