Axle Seal - Rear

This procedure covers the removal and replacement of the rear axle seal on a 2025 Rivian EDV 500 Dual Motor AWD electric delivery van, including rear differential fluid service.

Warnings

Tools required

Parts

• Rear axle seal × 1 — Use OEM Rivian specification
• Differential cover gasket (if applicable) × 1 — Use OEM specification
• Axle shaft O-ring (if equipped) × 1 — Use OEM specification
• Drain plug washer × 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. Power off the vehicle completely using the main power button
3. Disconnect the 12V battery negative terminal and wait 5 minutes for system capacitors to discharge
4. Raise vehicle on lift or use jack stands at manufacturer-specified lift points
5. Remove rear wheels on the side requiring seal replacement
6. Place wheel chocks in front of front tires for additional safety
7. Clean the rear differential and axle area with degreaser to prevent contamination during repair
8. Have drain pan and replacement fluid ready before beginning disassembly

Procedure

1. 1

   Remove rear brake caliper and rotor
   Remove the rear brake caliper mounting bolts and hang the caliper from the suspension or frame using a caliper hanger or sturdy wire. Do not let the caliper hang by the brake hose. Remove the brake rotor by removing any retaining screws and sliding it off the hub.
2. 2

   Disconnect ABS sensor and parking brake
   Locate the ABS wheel speed sensor connector near the axle and disconnect it. If equipped with electric parking brake, disconnect the parking brake actuator electrical connector. Remove any clips or brackets securing wiring to the axle or suspension components.
3. 3

   Drain rear differential fluid
   Position drain pan beneath the rear differential. Locate the differential drain plug (typically on the bottom or rear of the housing). Remove the drain plug and allow all gear oil to drain completely into the pan. Inspect drained fluid for metal particles or unusual contamination which may indicate additional internal damage.
4. 4

   Remove axle shaft retaining hardware
   Locate the axle shaft mounting bolts or retaining nuts at the hub assembly. These may be located behind the brake rotor mounting surface or at the outer end of the axle shaft. Remove all fasteners securing the axle shaft to the hub or differential. Note the orientation and position of any spacers or shims for reinstallation.
5. 5

   Extract axle shaft from differential
   Carefully pull the axle shaft straight out from the differential housing. It may require gentle persuasion with a soft mallet or slide hammer if it has not been removed previously. Be careful not to damage the splines on the axle shaft or inside the differential. Once removed, inspect the shaft for wear, scoring, or damage to sealing surfaces.
6. 6

   Remove old axle seal
   With the axle shaft removed, the old seal will be visible in the differential housing. Use an axle seal puller or carefully use a pry bar to extract the old seal from the housing. Work carefully to avoid damaging the seal bore in the housing. If the seal is stubborn, a slide hammer with seal puller attachment may be necessary. Clean the seal bore thoroughly with shop towels and inspect for damage, scoring, or pitting.
7. 7

   Inspect seal mating surfaces
   Examine the axle shaft seal surface (the area that contacts the seal lip) for grooves, wear, or damage. Use a micrometer or run your fingernail across the surface to detect any imperfections. Minor roughness can be smoothed with fine emery cloth, but deep grooves require shaft replacement. Inspect the seal bore in the differential housing for corrosion or damage that could prevent proper seal seating.
8. 8

   Install new axle seal
   Lightly coat the outer diameter of the new seal with gear oil. Apply a small amount of gear oil to the seal lip. Position the seal squarely in the bore with the lip facing inward toward the differential. Using a seal driver or appropriately sized socket that contacts only the outer edge of the seal, gently tap the seal into place until it is flush with the housing or seated to the proper depth. Ensure the seal is installed evenly and not cocked in the bore.
9. 9

   Prepare and reinstall axle shaft
   If equipped with a separate O-ring on the axle shaft splines, replace it with a new one lubricated with gear oil. Coat the axle shaft splines and seal contact surface with gear oil. Carefully align the axle shaft with the splines in the differential side gear and gently slide it into place. Ensure the shaft is fully seated and engages properly with the differential without damaging the new seal lip.
10. 10

    Secure axle shaft and reinstall hardware
    Install any spacers, shims, or washers in their original positions. Install the axle shaft retaining bolts or nuts and tighten them in a star pattern to ensure even pressure. Since specific torque values are not provided in the database, refer to the vehicle service manual or contact Rivian for proper torque specifications for axle mounting hardware.
11. 11

    Refill rear differential with gear oil
    Install a new washer on the differential drain plug and reinstall the plug. Locate the differential fill plug (typically on the side or top of the housing). Using a fluid pump, inject 75W-90 GL-5 gear oil into the fill hole until it reaches the bottom of the fill hole opening (approximately 2.0 quarts total). Allow a few minutes for oil to settle and top off if necessary. Reinstall the fill plug with a new washer if required.
12. 12

    Reconnect sensors and parking brake
    Reconnect the ABS wheel speed sensor connector and ensure it clicks into place securely. Reconnect the electric parking brake actuator connector if equipped. Secure all wiring with original clips and brackets, ensuring no wires are pinched or in contact with moving components or hot surfaces.
13. 13

    Reinstall brake rotor and caliper
    Clean the hub surface and rotor mating surface with brake cleaner. Install the brake rotor and secure with any retaining screws. Position the brake caliper over the rotor and install the caliper mounting bolts. Since specific torque values are not provided, refer to service manual specifications for proper caliper bolt torque.
14. 14

    Reinstall wheel and lower vehicle
    Install the rear wheel and hand-tighten lug nuts in a star pattern. Lower the vehicle until the tire just touches the ground. Torque the lug nuts to manufacturer specification (typically 125-150 ft-lbs for this vehicle class, but verify with Rivian documentation) in a star pattern. Fully lower the vehicle and remove jack stands.
15. 15

    Reconnect 12V battery and system check
    Reconnect the 12V battery negative terminal. Power on the vehicle and check for any warning lights or fault codes related to ABS, parking brake, or drivetrain systems. Use Rivian diagnostic software if available to clear any stored codes and verify all systems are functioning properly.

Reassembly

1. Ensure all electrical connectors are properly seated and secured with retaining clips
2. Verify brake pedal feels firm before moving vehicle and that parking brake functions correctly
3. Double-check that all fasteners have been reinstalled and properly torqued
4. Confirm differential is filled to proper level and both drain and fill plugs are secure

Verification

• With vehicle on level ground, inspect the rear differential area for any signs of gear oil leakage around the axle seal
• Test drive the vehicle at low speed and verify no unusual noises from the rear differential
• After test drive, re-inspect the seal area for any seepage or leaks
• Check ABS system functionality by performing a low-speed brake application and verifying no warning lights appear
• After 50-100 miles of driving, re-check differential fluid level and inspect seal area again for any delayed leakage
• Verify no fault codes are present in the vehicle system using diagnostic tools

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