Noise Diagnosis

Systematic diagnosis of noise concerns on the 2024 Rivian EDV 500 dual motor electric delivery vehicle, including identification of mechanical, electrical, and drivetrain noise sources.

Warnings

Tools required

Preparation

1. Obtain detailed customer complaint including when noise occurs (acceleration, deceleration, turning, braking, specific speeds)
2. Verify 12V battery is fully charged to prevent false diagnostic trouble codes
3. Connect Rivian diagnostic scanner and check for any stored DTCs related to motors, inverters, or drivetrain
4. Perform visual inspection of vehicle exterior for shipping damage, loose body panels, or aftermarket modifications
5. Place vehicle on level surface and set parking brake
6. Document baseline battery state of charge and thermal management system status

Procedure

1. 1

   Road test to reproduce noise
   Perform controlled road test with customer description in mind. Note exact conditions when noise occurs: vehicle speed, motor load (acceleration/deceleration/cruise), steering input, road surface type, and ambient temperature. Use digital sound level meter if available to establish baseline measurements. Record observations including frequency (Hz if measurable), duration, and whether noise is constant or intermittent. Test with HVAC and radio off to eliminate interior noise sources.
2. 2

   Inspect high voltage drive units
   Place vehicle in service mode per Rivian service procedures. Raise vehicle on lift and secure properly. Visually inspect front and rear drive units for signs of fluid leakage, impact damage, or loose mounting hardware. Check drive unit mounting bolts for proper torque and any signs of movement or fretting. Inspect CV axles and boots for tears, grease leakage, or damage. Listen to each drive unit area with automotive stethoscope while assistant rotates wheels by hand (vehicle in neutral, 12V disabled).
3. 3

   Examine differential and drivetrain components
   Check front and rear differential fluid levels through fill plugs. Inspect for contamination or metallic particles on magnetic fill plug. Verify 75W-90 GL-5 gear oil is at proper level (1.50 qt front, 2.00 qt rear capacity). Inspect driveline components for play or looseness. Check transfer case fluid level (2.50 qt capacity). Examine half shafts, CV joints, and wheel bearings for excessive play by grasping tire at 12 and 6 o'clock positions and attempting to rock wheel.
4. 4

   Inspect suspension and steering components
   With vehicle raised, inspect all suspension components for wear, damage, or looseness. Check control arm bushings, sway bar links, strut mounts, and ball joints. Examine steering rack boots for tears. Check power steering system (electric - no fluid) for proper operation and mounting security. Use pry bar to check for play in suspension joints. Inspect shock absorbers and struts for leakage or damage. Verify no contact between suspension components and body/frame.
5. 5

   Evaluate brake system for noise sources
   Remove wheels and inspect brake pads, rotors, and calipers. Check for uneven pad wear, glazing, or contamination. Verify brake pad wear sensors are functioning and not generating false noise. Check caliper slide pins for proper lubrication and movement. Inspect brake shield backing plates for contact with rotor. Measure rotor thickness and lateral runout with dial indicator. Check for loose caliper mounting hardware or brake line contact points.
6. 6

   Inspect wheels, tires, and wheel bearings
   Examine all tires for irregular wear patterns, embedded objects, tread separation, or belt issues that could cause noise. Check tire pressures and compare to door placard specifications for EDV 500. Verify wheel balance and inspect wheels for damage, cracks, or improper mounting. Test wheel bearings by rotating wheel and listening/feeling for roughness or grinding. Check for excessive radial or axial play in wheel bearing assemblies.
7. 7

   Examine body and interior noise paths
   Inspect cargo area mounting points, shelving brackets, and package restraint systems for looseness. Check door seals, weatherstripping, and panel fit for wind noise sources. Examine underbody shields, splash guards, and aerodynamic panels for security and damage. Verify exhaust heat shields (if equipped with auxiliary heater) are secure. Check HVAC system blower motor and cabin air filter for debris or obstruction.
8. 8

   Analyze electric motor and inverter operation
   Using Rivian diagnostic scanner, monitor motor RPM, torque output, and temperature data during controlled test. Review inverter output waveforms if available in diagnostic software. Check for any intermittent DTCs related to motor position sensors or resolver faults. Verify motor cooling system is operating properly - check EV Battery/Motor Coolant level (10.00 qt capacity) and inspect cooling lines for leaks or air pockets. Listen for abnormal sounds from motor cooling pump.
9. 9

   Inspect high voltage battery thermal management
   Check battery pack mounting for security and any signs of road debris impact. Inspect battery thermal management system coolant lines for leaks, damage, or improper routing that could cause contact noise. Verify battery cooling pump operation is smooth without cavitation or bearing noise. Check battery pack vent system for obstruction. Review battery cell temperatures in diagnostic scanner for any imbalance that might indicate internal issues.
10. 10

    Test accessory systems and auxiliary components
    Operate all accessory systems individually to isolate potential noise sources: HVAC blower at all speeds, wipers, power mirrors, power windows. Check washer pump operation (3.50 qt capacity system). Test 12V auxiliary battery condition and charging system. Inspect 12V DC-DC converter for mounting security and abnormal operation. Verify air compressor (if equipped) cycles normally without excessive noise.
11. 11

    Perform pinpoint diagnosis with chassis ears
    If noise source remains unclear, install chassis ear sensors at suspected locations: each drive unit, differential locations, suspension mounting points, and body mount areas. Conduct controlled road test or dynamometer test while monitoring each sensor location. Isolate the specific component or area generating the noise. Cross-reference findings with diagnostic scanner data to identify any correlation with vehicle speed, motor RPM, or electrical system operation.
12. 12

    Document findings and determine root cause
    Compile all diagnostic data including road test observations, visual inspection findings, scanner data, and acoustic testing results. Determine root cause of noise: mechanical wear, loose component, normal operating characteristic, or design-related issue. Verify findings against Rivian Technical Service Bulletins for known noise concerns on EDV 500 platform. Prepare detailed diagnostic report with recommended repairs or confirmation that noise is within normal operating parameters.

Reassembly

1. Reinstall all wheels and torque lug nuts to specification in star pattern
2. Lower vehicle from lift and perform final walk-around inspection
3. Clear service mode and restore vehicle to normal operating condition
4. Verify all diagnostic equipment is disconnected

Verification

• Perform confirmation road test following same route and conditions as initial test drive
• Verify noise concern is accurately documented and root cause identified
• Confirm all DTCs are addressed and no new codes are present
• Document findings in repair order with specific recommendations for correction if applicable
• If noise cannot be duplicated, provide customer with detailed explanation of inspection performed and recommend monitoring

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