Differential Service

Service the front and rear differentials on the Rivian EDV 500 dual motor AWD system by draining old gear oil, inspecting for metal particles, and refilling with fresh 75W-90 GL-5 gear oil.

Warnings

Tools required

Parts

• Front differential drain plug washer × 1 — Use OEM specification
• Front differential fill plug washer × 1 — Use OEM specification
• Rear differential drain plug washer × 1 — Use OEM specification
• Rear differential fill plug washer × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 3.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure high voltage system is in service mode if required by manufacturer (consult service manual)
3. Allow differentials to cool to ambient temperature if vehicle was recently operated
4. Raise vehicle on lift or securely support on jack stands at all four corners
5. Remove underbody panels or skid plates if they obstruct access to differential drain and fill plugs
6. Clean area around differential drain and fill plugs with wire brush and shop towels to prevent contamination

Procedure

1. 1

   Locate front differential service points
   Position yourself under the front of the vehicle. Identify the front differential housing integrated with the front motor assembly. Locate the fill plug (upper position) and drain plug (lower position) on the differential housing. Clean both plug areas thoroughly with a wire brush.
2. 2

   Remove front differential fill plug first
   Using appropriate socket, loosen and remove the front differential fill plug. This ensures you can refill the differential after draining. If fill plug is seized or cannot be removed, do not proceed with draining. Inspect the fill plug washer for damage.
3. 3

   Drain front differential
   Position drain pan under front differential drain plug. Remove the drain plug and allow gear oil to drain completely (approximately 1.5 quarts). Inspect drained fluid for metal particles, discoloration, or contamination. Excessive metal debris may indicate internal wear requiring further inspection.
4. 4

   Inspect and reinstall front differential drain plug
   Clean the drain plug with shop towel and inspect the magnetic tip for metal particles (normal fine metallic residue is acceptable). Clean the drain plug threads and sealing surface. Install new drain plug washer and reinstall drain plug. Note: Torque specification not available in database - consult factory service manual for proper torque value.
5. 5

   Refill front differential
   Using fluid pump or squeeze bottle, inject 1.5 quarts of fresh 75W-90 GL-5 gear oil through the fill hole. Fill until oil begins to seep from the fill hole opening, indicating proper level. Allow excess to drain back for 30 seconds.
6. 6

   Reinstall front differential fill plug
   Clean the fill plug threads and install new fill plug washer. Thread fill plug in by hand first to prevent cross-threading, then tighten. Note: Torque specification not available in database - consult factory service manual for proper torque value.
7. 7

   Locate rear differential service points
   Move to the rear of the vehicle. Identify the rear differential housing integrated with the rear motor assembly. Locate the fill plug (upper position) and drain plug (lower position) on the rear differential housing. Clean both plug areas thoroughly with a wire brush.
8. 8

   Remove rear differential fill plug first
   Using appropriate socket, loosen and remove the rear differential fill plug. As with the front, verify the fill plug can be removed before draining. Inspect the fill plug washer for damage and set aside for replacement.
9. 9

   Drain rear differential
   Position drain pan under rear differential drain plug. Remove the drain plug and allow gear oil to drain completely (approximately 2.0 quarts). Inspect drained fluid for metal particles, discoloration, or contamination. The rear differential typically shows more wear debris than front due to higher load during acceleration.
10. 10

    Inspect and reinstall rear differential drain plug
    Clean the drain plug with shop towel and inspect the magnetic tip for metal particles. Clean the drain plug threads and sealing surface. Install new drain plug washer and reinstall drain plug. Note: Torque specification not available in database - consult factory service manual for proper torque value.
11. 11

    Refill rear differential
    Using fluid pump or squeeze bottle, inject 2.0 quarts of fresh 75W-90 GL-5 gear oil through the fill hole. Fill until oil begins to seep from the fill hole opening, indicating proper level. Allow excess to drain back for 30 seconds.
12. 12

    Reinstall rear differential fill plug
    Clean the fill plug threads and install new fill plug washer. Thread fill plug in by hand first to prevent cross-threading, then tighten. Note: Torque specification not available in database - consult factory service manual for proper torque value.

Reassembly

1. Wipe any spilled gear oil from differential housings and surrounding components
2. Reinstall any underbody panels or skid plates that were removed for access
3. Lower vehicle to ground
4. If high voltage system was placed in service mode, restore to normal operation per manufacturer procedure

Verification

• Check all drain and fill plugs for proper tightness and verify no leaks are present
• Start vehicle and allow motor systems to initialize (no actual engine running on EV)
• Perform short test drive including forward and reverse operation, acceleration, and turns in both directions
• Re-check differential plugs for leaks after test drive
• Verify no unusual noises from front or rear differential assemblies during operation
• Reset service interval indicator if equipped with differential service reminder

Related trouble codes on this vehicle

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