This procedure covers the removal and replacement of an ABS tone ring on a 2025 Rivian EDV 500 electric delivery van with dual motor AWD configuration.

Warnings

Tools required

Parts

• ABS tone ring × 1 — Use OEM specification for specific axle position
• Hub nut (if required) × 1 — Use OEM specification
• Anti-seize compound × 1 — Copper-based high-temp

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind wheels opposite of repair location
3. Connect OBD-II scan tool and document any existing ABS fault codes
4. Disconnect 12V auxiliary battery (located in front compartment) and wait 2 minutes for system capacitors to discharge
5. Verify high-voltage system is in service mode (consult Rivian service documentation for proper HV isolation procedure)
6. Lift vehicle using designated lift points and support with jack stands rated for commercial EV weight
7. Remove wheel and tire assembly from affected corner

Procedure

1. 1

   Inspect ABS sensor and document tone ring condition
   Before removal, visually inspect the ABS wheel speed sensor and existing tone ring. Document any physical damage, corrosion, or debris accumulation. Check sensor air gap with feeler gauge if accessible (typical specification 0.020-0.040 inches). Take photos for reference during reassembly.
2. 2

   Remove ABS wheel speed sensor
   Disconnect the ABS wheel speed sensor electrical connector by releasing the locking tab. Remove the sensor mounting bolt and carefully extract the sensor from its housing. Do not pry against the sensor tip. Clean the sensor bore with brake cleaner and inspect for debris or damage.
3. 3

   Remove brake caliper and rotor
   Remove the brake caliper mounting bolts and suspend the caliper from the suspension using a wire or bungee cord - do not let it hang by the brake hose. Remove the caliper bracket mounting bolts and set aside. Slide the brake rotor off the hub. If rotor is seized, use penetrating oil and light tapping with rubber mallet.
4. 4

   Remove hub/bearing assembly or axle nut
   Depending on which tone ring location is being serviced (some EDV 500 configurations use tone rings on the CV axle, others on the hub bearing), either remove the hub bearing assembly mounting bolts from the knuckle, or remove the large axle nut using a breaker bar and appropriate socket. If removing hub assembly, support it to prevent damage to the wheel studs.
5. 5

   Remove damaged ABS tone ring
   Inspect how the tone ring is retained - it may be pressed on, mechanically fastened, or integrated into a component. If pressed on, carefully use a punch and hammer to tap the ring in a circular pattern to walk it off the hub or axle. If mechanically fastened, remove retaining hardware. Avoid damaging the mounting surface. Clean the mounting surface thoroughly with brake cleaner and wire brush.
6. 6

   Prepare new tone ring and mounting surface
   Clean the new ABS tone ring with brake cleaner to remove any protective coating or debris. Inspect the tone ring teeth for any damage or irregularities - reject if defective. Clean the hub or axle mounting surface with brake cleaner until completely free of rust, old adhesive, or debris. Apply a thin coat of anti-seize to the mounting surface if specified by manufacturer.
7. 7

   Install new ABS tone ring
   Align the new tone ring on the hub or axle shaft, ensuring proper orientation (some tone rings are directional - check for markings). If press-fit type, use a proper driver tool or socket that contacts only the inner ring surface, never the teeth. Tap evenly in a circular pattern until fully seated. If mechanically fastened, install retaining hardware and secure per manufacturer specifications.
8. 8

   Verify tone ring installation and runout
   Verify the tone ring is fully seated with no gaps between ring and mounting surface. If available, use a dial indicator to check radial runout - should be less than 0.030 inches for most applications. Rotate the hub or axle by hand while holding the dial indicator against the tone ring outer diameter. Excessive runout will cause erratic ABS operation.
9. 9

   Reinstall hub/bearing assembly
   Reinstall the hub bearing assembly or axle nut that was removed earlier. If reinstalling hub bearing, install mounting bolts and tighten in a star pattern. If installing axle nut, torque to manufacturer specification (typically 150-200 ft-lbs for vehicles of this class, but verify with Rivian documentation as no specific torque spec is available in database).
10. 10

    Reinstall brake components
    Reinstall the brake rotor, ensuring it seats flat against the hub surface. Install the caliper bracket and mounting bolts. Reinstall the brake caliper over the rotor and install caliper mounting bolts. Verify the brake pads are properly positioned and the caliper slides freely.
11. 11

    Reinstall ABS wheel speed sensor
    Clean the ABS sensor tip with brake cleaner - do not use abrasives. Apply a small amount of dielectric grease to the sensor O-ring if equipped. Install the sensor into its bore, ensuring it seats fully. Install the sensor mounting bolt and tighten securely but do not overtighten (typically 8-12 ft-lbs). Reconnect the electrical connector until it clicks.
12. 12

    Reinstall wheel and lower vehicle
    Reinstall the wheel and tire assembly. Install lug nuts and tighten in a star pattern to manufacturer specification (typically 120-150 ft-lbs for this vehicle class). Lower the vehicle to the ground and perform final lug nut torque check with wheels loaded.

Reassembly

1. Ensure all fasteners are tightened to specification and no tools or parts are left in the wheel well
2. Reconnect the 12V auxiliary battery
3. Exit service mode and restore normal vehicle operation per Rivian service procedures
4. Pump brake pedal several times to ensure proper brake pad seating before moving vehicle

Verification

• Connect OBD-II scan tool and clear any ABS fault codes stored during the repair
• Perform a wheel speed sensor test using the scan tool - all four sensors should show 0 mph with vehicle stationary
• Conduct a low-speed test drive (under 10 mph) in a safe area and verify all wheel speed sensors are reading on the scan tool
• Accelerate to 25 mph and verify ABS warning light remains off and all sensors show similar speeds
• Perform a controlled ABS activation test in a safe area if equipped with ABS test function, or verify normal ABS operation during a controlled stop on low-traction surface
• Verify no abnormal noises from the wheel bearing area during test drive
• Re-scan for fault codes after test drive to confirm repair is successful

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