Replace the front axle seal on a 2025 Rivian EDV 500 to prevent differential fluid leaks. This procedure involves removing the front halfshaft, extracting the old seal, and installing a new seal.

Warnings

Tools required

Parts

• Front axle seal × 1 — Use OEM specification
• Axle nut × 1 — Use OEM specification
• Lower control arm ball joint nut (if damaged) × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect the 12V battery negative terminal and wait 5 minutes for system discharge
3. Raise vehicle on lift or jack stands ensuring proper weight rating for electric vehicle
4. Remove the front wheel on the side requiring seal replacement
5. Place drain pan under front differential to catch gear oil
6. Mark the position of the halfshaft relative to the differential for reassembly reference

Procedure

1. 1

   Remove axle nut and brake caliper
   With wheel removed, use a breaker bar and axle nut socket to remove the front axle nut. Remove the brake caliper mounting bolts and hang the caliper from the suspension using wire or a bungee cord to avoid stressing the brake line. Remove the brake rotor.
2. 2

   Disconnect lower ball joint
   Remove the lower control arm ball joint nut. Use a ball joint separator or pickle fork to disconnect the lower ball joint from the steering knuckle. Apply penetrating oil if the joint is tight and tap the separator with a hammer to break the taper.
3. 3

   Disconnect outer CV joint from hub
   Push the steering knuckle assembly outward while pulling the halfshaft out of the wheel hub. If the shaft is stuck in the hub, use a dead blow hammer on the end of the shaft to break it free. Be careful not to damage the ABS sensor or wiring.
4. 4

   Remove halfshaft from differential
   Position drain pan directly under the differential seal area. Insert a pry bar between the inner CV joint housing and the differential case. Carefully pry the halfshaft out of the differential, using the circlip groove as a leverage point. Pull the entire halfshaft assembly out and set aside on a clean surface. Allow gear oil to drain into the pan.
5. 5

   Remove old axle seal
   Inspect the seal area and note the orientation of the seal. Use a seal puller or carefully insert a flat-blade screwdriver behind the seal lip to pry it out of the differential housing. Work around the circumference to avoid cocking the seal. Remove the seal completely and inspect the seal bore for damage or scoring.
6. 6

   Clean seal bore and prepare for installation
   Use a wire brush and brake cleaner to thoroughly clean the seal bore in the differential housing. Remove all old seal material, dirt, and debris. Inspect the bore for scratches or damage that could compromise the new seal. Clean the area around the differential opening as well.
7. 7

   Install new axle seal
   Lightly coat the outer edge of the new seal with gear oil. Position the seal squarely in the bore with the seal lip facing inward toward the differential. Use a seal driver that matches the seal diameter to tap the seal evenly into place. Drive the seal until it is flush with or slightly below the housing surface, following the same depth as the original seal.
8. 8

   Inspect and prepare halfshaft
   Inspect the halfshaft splines and seal contact area for damage, scoring, or excessive wear. Clean the splines with brake cleaner. Inspect the circlip on the inner CV joint and ensure it is properly seated in its groove. Replace the circlip if it shows signs of deformation or wear.
9. 9

   Reinstall halfshaft into differential
   Apply a thin coat of gear oil to the seal lip and the halfshaft seal contact area. Align the halfshaft splines with the differential side gear and carefully push the shaft into the differential. You should feel resistance as the circlip compresses, then a positive click or snap when the circlip seats in the differential groove. Pull outward on the halfshaft to verify it is locked in place.
10. 10

    Reconnect halfshaft to hub and ball joint
    Insert the outer CV joint stub shaft into the wheel hub, aligning the splines. Install a new axle nut but do not fully tighten yet. Reconnect the lower ball joint to the steering knuckle and install the ball joint nut. Tighten the ball joint nut to specification (refer to manufacturer guidelines).
11. 11

    Reinstall brake components
    Reinstall the brake rotor onto the hub. Remove the caliper from its support and reinstall it over the rotor. Install the caliper mounting bolts and tighten to specification.
12. 12

    Torque axle nut and reinstall wheel
    With the vehicle still raised, torque the axle nut to the manufacturer specification (typically 180-220 ft-lbs for this vehicle class). Stake or install the locking mechanism for the axle nut per Rivian specifications. Reinstall the wheel and torque the lug nuts to specification in a star pattern.
13. 13

    Refill front differential
    Locate the front differential fill plug. Using a fluid pump or funnel with hose, add 75W-90 GL-5 gear oil until it begins to overflow from the fill hole or reaches the proper level (approximately 1.5 quarts). Install the fill plug and tighten to specification.

Reassembly

1. Ensure all fasteners are torqued to manufacturer specifications
2. Verify the halfshaft is fully seated in the differential by attempting to pull it out
3. Double-check that brake caliper bolts are properly torqued and the caliper moves freely
4. Confirm the axle nut is properly staked or locked per Rivian specifications

Verification

• Lower the vehicle and reconnect the 12V battery
• Start the vehicle and check for any warning lights related to drivetrain or ABS systems
• Test drive the vehicle at low speed and verify smooth operation without clicking, grinding, or vibration from the front axle
• After test drive, raise the vehicle and inspect the new seal area for any signs of gear oil leakage
• Recheck differential fluid level after test drive and top off if necessary
• Verify no gear oil spots under the vehicle after it has been parked for several hours

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