Axle Shaft - Rear

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

Warnings

Tools required

Parts

• Rear axle shaft assembly × 1 — Use OEM Rivian specification
• Axle seal × 1 — Use OEM specification
• Wheel hub nut × 1 — Single-use fastener
• Differential cover gasket or RTV sealant × 1 — Use OEM specification
• Brake caliper mounting bolts × 2 — If thread-locking compound damaged

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and apply parking brake to front wheels only
2. Place wheel chocks in front of both front wheels
3. Disconnect 12V negative battery cable and wait 10 minutes for system capacitor discharge
4. Verify high-voltage system is in safe service mode using dashboard indicators
5. Raise vehicle on lift to working height ensuring proper lift point contact per manufacturer specifications
6. Remove rear wheel on side requiring axle shaft service
7. Engage transmission in Park mode mechanically if electronic park brake is non-functional

Procedure

1. 1

   Remove brake caliper assembly
   Remove the two brake caliper mounting bolts and carefully support the caliper with a bungee cord or wire to avoid stress on the brake hose. Do not allow caliper to hang by the brake line. Inspect brake pads for wear and note condition for reassembly.
2. 2

   Remove brake rotor
   Remove the brake rotor retaining screws if present. If rotor is seized to the hub, use a rubber mallet to tap around the perimeter to break it free. On EDV models, the rotor may have corrosion due to delivery route stop-and-go cycles.
3. 3

   Remove wheel hub nut
   Remove the axle hub retaining nut using a breaker bar and appropriate socket. This nut is typically torqued to very high specification and is a single-use fastener. Have an assistant apply brake pressure or use a wheel hub holding tool to prevent rotation. Discard the old nut.
4. 4

   Disconnect wheel speed sensor
   Locate the wheel speed sensor connector near the rear suspension mounting point. Carefully disconnect the electrical connector by depressing the locking tab. On EDV models, this sensor feeds data to both ABS and traction control systems. Inspect connector for corrosion.
5. 5

   Remove hub bearing assembly bolts
   Access the hub bearing assembly mounting bolts from the rear of the knuckle or suspension housing. Remove all mounting bolts and carefully extract the hub bearing assembly. Some force may be required if corrosion is present. Do not damage the backing plate or ABS sensor mounting surface.
6. 6

   Position drain pan and prepare for fluid loss
   Position a drain pan with minimum 3-quart capacity beneath the differential area where the axle shaft enters the housing. Expect approximately 2 quarts of 75W-90 gear oil to drain during axle extraction. Have shop towels ready to contain spillage.
7. 7

   Extract axle shaft from differential
   Using a slide hammer with appropriate axle puller adapter attached to the axle shaft stub, carefully extract the axle shaft from the differential housing. Apply steady force in multiple cycles rather than one sharp pull. The C-clip or retaining ring inside the differential must clear the side gear before the shaft will release. Once resistance decreases, pull the shaft completely free and allow gear oil to drain into the pan.
8. 8

   Remove and inspect axle seal
   With the axle shaft removed, inspect the differential side seal. Use a seal puller or pry bar with protective covering to carefully remove the old axle seal from the differential housing. Inspect the seal bore for scoring, corrosion, or damage that could compromise the new seal. Clean the seal mounting surface thoroughly with a lint-free cloth.
9. 9

   Inspect differential internal components
   With the axle removed, visually inspect the differential side gears and C-clip groove if accessible. Look for abnormal wear patterns, metal shavings, or damaged teeth. On electric AWD systems, differential wear patterns may differ from conventional vehicles due to instant torque delivery. Check for proper C-clip seating if your vehicle uses this retention method.
10. 10

    Install new axle seal
    Apply a thin coat of fresh 75W-90 gear oil to the outer diameter and sealing lip of the new axle seal. Using a seal driver of appropriate diameter or the differential seal installation tool, carefully drive the new seal into the housing bore until it seats flush. Ensure the seal is installed squarely and evenly to prevent leakage. The seal lip should face inward toward the differential.
11. 11

    Prepare and install new axle shaft
    Inspect the new axle shaft splines for damage or burrs. Apply a light coating of 75W-90 gear oil to the shaft splines and seal contact area. Carefully align the axle shaft splines with the differential side gear and push the shaft into the housing. You may need to rotate the shaft slightly to align splines. Push firmly until you feel or hear the C-clip or retaining mechanism engage. Pull back on the shaft to verify it is locked in place.
12. 12

    Refill rear differential
    Using a gear oil pump, refill the rear differential with 75W-90 GL-5 gear oil to the proper level. The EDV 500 rear differential capacity is 2.0 quarts. Fill until oil begins to seep from the fill hole, then install and tighten the fill plug. Wipe away excess oil from the housing exterior.
13. 13

    Reinstall hub bearing assembly
    Position the hub bearing assembly onto the knuckle or suspension housing, aligning all mounting bolt holes. Install the mounting bolts and tighten in a star pattern to ensure even seating. While no torque specifications are provided in the database, follow manufacturer specifications from service manual for your specific model.
14. 14

    Install new wheel hub nut
    Install the new single-use wheel hub nut onto the axle shaft threads. Hand-tighten the nut, then torque to manufacturer specification. This nut typically requires torque in the range of 150-200 ft-lbs on commercial electric vehicles, but verify with official service documentation. Use proper technique to prevent hub bearing preload issues.
15. 15

    Reconnect wheel speed sensor and reinstall brake components
    Reconnect the wheel speed sensor electrical connector ensuring the locking tab clicks into place. Reinstall the brake rotor and secure with retaining screws if equipped. Reinstall the brake caliper assembly and torque mounting bolts per manufacturer specification. Verify brake pads are properly seated and caliper moves freely.

Reassembly

1. Reinstall the rear wheel and hand-tighten lug nuts in a star pattern
2. Lower vehicle to ground and torque wheel lug nuts to manufacturer specification in star pattern
3. Reconnect 12V negative battery cable
4. Cycle ignition to ON position and verify no ABS or traction control warning lights are present
5. Perform initial system check of electric drive system per manufacturer diagnostic procedures

Verification

• Test drive vehicle in a safe area at low speed to verify no abnormal noises from rear axle
• Verify ABS and traction control systems function properly during test drive
• Inspect rear differential area for any signs of gear oil leakage after test drive
• Verify wheel speed sensor is providing proper signal using diagnostic scan tool if available
• Check that electronic parking brake engages and releases properly if integrated with rear motor assembly
• Perform regenerative braking test to ensure rear motor torque is transmitted properly through new axle shaft
• Re-torque wheel lug nuts after 50-100 miles of operation

More procedures for this vehicle