CV Axle - Rear

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

Warnings

Tools required

Parts

• Rear CV axle assembly × 1 — Use OEM Rivian specification
• Axle hub nut × 1 — Use OEM specification (single-use)
• Differential seal (inboard side) × 1 — Use OEM specification
• CV axle circlip (if not included with axle) × 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. Place wheel chocks at front wheels
3. Follow Rivian high-voltage lockout/tagout procedures to de-energize the traction battery system
4. Verify high-voltage system is de-energized using approved voltage tester
5. Lift vehicle using approved lift points and secure on jack stands rated for EV weight
6. Remove rear wheel on the side requiring CV axle replacement
7. Position drain pan under rear differential on affected side

Procedure

1. 1

   Remove hub nut
   With the vehicle still on the ground or while having an assistant apply brakes, use a breaker bar to loosen the rear axle hub nut. Do not remove completely yet. This nut is typically torqued to a very high specification and may require significant force to break free.
2. 2

   Remove brake caliper
   Remove the brake caliper mounting bolts and carefully hang the caliper from the suspension using a wire or bungee cord. Do not let the caliper hang by the brake hose. Remove the brake rotor if it interferes with access to the hub area.
3. 3

   Disconnect wheel speed sensor
   Locate the rear wheel speed sensor connector near the suspension mounting point. Disconnect the electrical connector and carefully unclip the wiring harness from any retaining clips along the suspension arm or knuckle.
4. 4

   Remove suspension lower control arm connection
   Remove the bolt connecting the lower suspension control arm to the steering knuckle. This will provide additional clearance for CV axle removal. Support the control arm to prevent it from dropping suddenly.
5. 5

   Remove hub nut completely
   Now that the vehicle is raised and secured, remove the hub nut completely. Set aside for disposal as this is a single-use fastener. Note any washers or spacers present and their orientation.
6. 6

   Separate CV axle from wheel hub
   Push the CV axle shaft back through the wheel hub assembly. If the axle is stuck in the hub splines, use a soft-faced mallet to tap on the end of the shaft, or use a hub puller tool. Be careful not to damage the CV joint boot or threads on the axle shaft.
7. 7

   Support the CV axle outboard end
   Once the axle is free from the hub, support the outer end of the CV axle to prevent it from hanging and damaging the inboard joint or differential seal during the next steps.
8. 8

   Remove CV axle from differential
   Position the drain pan directly under the differential-to-axle connection point. Using a pry bar positioned between the inner CV joint housing and the differential case, carefully pry the axle from the differential. Apply steady pressure until the circlip releases and the axle pulls free. Expect 0.5-1.0 quarts of gear oil to drain out. Avoid prying against the motor housing or any aluminum sealing surfaces.
9. 9

   Remove CV axle assembly
   Carefully maneuver the CV axle assembly out from between the suspension components and chassis. Note the routing path for installation of the new axle. Inspect the removed axle for the type of failure or wear pattern.
10. 10

    Inspect and replace differential seal
    Inspect the differential seal where the CV axle was removed. If the seal shows any signs of wear, damage, or leakage, use a seal puller to remove it and press in a new seal using an appropriately sized seal driver. Ensure the seal is flush and properly seated.
11. 11

    Prepare new CV axle
    Remove the new CV axle from packaging and inspect for damage during shipping. Verify that a new circlip is installed on the inner CV joint splines (or install one if not present). Lightly lubricate the circlip and splines with clean gear oil. Check that the hub splines on the outboard end are clean and free of burrs.
12. 12

    Install new CV axle into differential
    Align the inner CV joint with the differential opening. Push the axle shaft firmly into the differential until you hear and feel the circlip seat into its groove. Give the axle a firm pull outward to verify the circlip is properly engaged and the axle will not pull free.
13. 13

    Install CV axle into wheel hub
    Carefully guide the outboard end of the CV axle through the wheel hub assembly, aligning the splines. It may be necessary to rotate the hub slightly to align the splines. Push the axle through until it is fully seated in the hub.
14. 14

    Install new hub nut
    Thread the new hub nut onto the axle shaft by hand as far as possible. Ensure any washers or spacers noted during removal are reinstalled in the correct orientation. Do not torque the nut yet.
15. 15

    Reconnect suspension and brake components
    Reinstall the lower control arm bolt to the steering knuckle. Reconnect the wheel speed sensor electrical connector and secure the wiring harness to all original retaining clips. Reinstall the brake rotor (if removed) and remount the brake caliper to its bracket.
16. 16

    Refill rear differential
    Locate the rear differential fill plug. Using a fluid transfer pump, add 75W-90 GL-5 gear oil until it begins to seep from the fill hole, indicating the proper level (approximately 2.0 quarts). Reinstall and tighten the fill plug.
17. 17

    Torque hub nut and final assembly
    Reinstall the rear wheel and lower the vehicle until the tire just contacts the ground to prevent hub rotation. Torque the hub nut to manufacturer specification (typically 150-200 ft-lb for this application, but verify with Rivian service information as no specific torque was provided in the database). Fully lower the vehicle and perform final torque on all fasteners.

Reassembly

1. Ensure all electrical connectors are fully seated and secured
2. Verify wheel lug nuts are torqued to Rivian specification
3. Double-check that the rear differential is filled to the proper level
4. Remove high-voltage lockout devices and re-energize the vehicle system following Rivian procedures
5. Clear any diagnostic trouble codes that may have been set during the high-voltage lockout

Verification

• Start the vehicle and verify no warning lights are present on the instrument cluster
• Test drive the vehicle at low speed in a safe area, listening for any clicking, grinding, or abnormal noises from the rear axle during acceleration, deceleration, and turning
• Verify smooth power delivery with no vibration or shuddering
• Re-check the rear differential fluid level after test drive and top off if necessary
• Inspect the differential and CV joint boots for any signs of leakage
• Verify wheel speed sensor operation by checking ABS and traction control system function

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