Axle Seal - Rear

This procedure covers the replacement of the rear axle seal on a 2024 Rivian EDV 500, including removal of the rear halfshaft, seal extraction, installation of new seal, and rear differential fluid replacement.

Warnings

Tools required

Parts

• Rear axle seal × 1 — Use OEM Rivian specification
• Axle nut (if equipped with non-reusable type) × 1 — Use OEM specification
• Differential drain plug gasket/washer × 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. Power down the vehicle completely using the center screen shutdown procedure
3. Disconnect the 12V battery negative terminal and wait 5 minutes for system capacitor discharge
4. Raise vehicle on lift or jack stands at designated lift points, ensuring secure support
5. Remove rear wheel on the side requiring axle seal replacement
6. Place drain pan under rear differential
7. Mark the affected side (driver or passenger) to ensure correct reassembly orientation

Procedure

1. 1

   Remove rear brake caliper and rotor
   Remove the brake caliper mounting bolts and carefully hang the caliper from the suspension using wire or a caliper hanger to avoid stressing the brake line. Remove the brake rotor retaining screw if present, then slide the rotor off the hub.
2. 2

   Remove axle nut
   Have an assistant apply the brake pedal or use a pry bar to prevent hub rotation. Use a breaker bar and 32mm socket to loosen and remove the rear axle nut. Note whether the axle nut is a prevailing torque type that requires replacement.
3. 3

   Disconnect suspension components
   Disconnect the lower control arm and any other suspension components that interfere with halfshaft removal. On the EDV 500, this typically includes the lower control arm ball joint and trailing arm connection. Support the suspension with a jack if necessary to relieve load.
4. 4

   Drain rear differential fluid
   Locate the rear differential drain plug on the bottom of the differential housing. Position drain pan directly underneath. Remove the drain plug and allow all gear oil to drain completely (approximately 2 quarts). Inspect drained fluid for metal particles or contamination that may indicate additional internal damage.
5. 5

   Remove halfshaft from hub
   Push the halfshaft inward through the hub assembly to disengage the splines. If stuck, use a brass drift or plastic mallet to tap the end of the shaft. The shaft should push through the hub bearing. Do not strike the shaft with excessive force.
6. 6

   Remove halfshaft from differential
   Using a pry bar positioned against the differential housing (not the seal), carefully pry the inner CV joint outward to disengage the circlip from the differential side gear. Pull the entire halfshaft assembly out and support it to prevent damage. Place on clean surface or suspend from chassis.
7. 7

   Extract old axle seal
   Using a seal puller or slide hammer with appropriate attachment, carefully extract the old axle seal from the differential housing. Be extremely careful not to score or damage the seal bore surface in the differential housing, as this will cause the new seal to leak. If the seal is stubborn, work around the entire circumference evenly.
8. 8

   Clean and inspect seal bore
   Thoroughly clean the seal bore in the differential housing using a wire brush and clean rags. Remove all old seal material, debris, and buildup. Inspect the bore for scoring, pitting, or damage. Use a flashlight to inspect the differential side gear and splines for wear. If damage is present, additional repairs may be required.
9. 9

   Inspect halfshaft seal surface
   Examine the seal riding surface on the halfshaft for wear grooves, scoring, or corrosion. Use a fingernail to check for any ridges or imperfections. If significant wear is present, the halfshaft should be replaced as it will cause premature seal failure. Light surface rust can be cleaned with fine emery cloth.
10. 10

    Install new axle seal
    Lightly coat the outer diameter of the new seal with gear oil. Position the seal squarely in the bore with the seal lip facing inward toward the differential. Using a seal driver or appropriately sized socket that contacts only the outer edge of the seal, drive the seal into the bore evenly until it seats flush with the housing face or reaches the internal stop. Apply light coat of gear oil to the seal lip.
11. 11

    Reinstall halfshaft into differential
    Ensure the inner CV joint circlip is properly installed and in good condition. Align the halfshaft splines with the differential side gear. Push the halfshaft firmly into the differential until the circlip engages with an audible click. Tug outward on the shaft to verify the circlip is fully seated and the shaft will not pull out.
12. 12

    Reinstall halfshaft into hub
    Guide the outer end of the halfshaft through the hub bearing, ensuring proper spline alignment. Push the shaft fully through until the threads protrude beyond the hub face. Install the axle nut hand-tight at this stage.
13. 13

    Refill rear differential
    Install new drain plug gasket/washer and reinstall the drain plug. Locate the differential fill plug (typically on the side of the housing). Remove the fill plug and use a fluid pump to add 75W-90 GL-5 gear oil until it reaches the bottom of the fill hole (approximately 2.0 quarts). Allow fluid to settle for 1 minute, then top off if necessary. Reinstall fill plug.
14. 14

    Reconnect suspension and torque axle nut
    Reconnect all suspension components that were disconnected during disassembly. Install the brake rotor and caliper. With an assistant applying the brake or using a pry bar to prevent rotation, torque the axle nut to manufacturer specification. Note: Torque specification not available in database - consult Rivian service information for proper value. Stake or install cotter pin if applicable.

Reassembly

1. Reinstall the rear wheel and torque lug nuts to specification in a star pattern
2. Lower the vehicle to the ground
3. Reconnect the 12V battery negative terminal
4. Power up the vehicle and check for any fault codes related to drivetrain or suspension sensors
5. Torque specifications not provided in database - consult official Rivian service information for all critical fastener torque values including axle nut, suspension components, caliper bolts, and drain/fill plugs

Verification

• Test drive the vehicle at various speeds and listen for any unusual noises from the rear differential area
• After test drive (approximately 10-15 miles), re-check the differential fluid level at the fill plug with vehicle on level surface - top off if necessary
• Inspect the area around the new axle seal for any signs of gear oil leakage
• Verify no warning lights are illuminated on the instrument cluster
• Re-check axle nut torque after 50-100 miles of driving
• Monitor the seal area for leakage over the next several days of operation

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