Axle Shaft - Rear

This procedure covers the removal and replacement of the rear axle shaft (CV axle) on a 2025 Rivian EDV 500 with dual motor AWD system.

Warnings

Tools required

Parts

• Rear axle shaft assembly × 1 — Use OEM specification
• Axle shaft retaining circlip × 1 — Use OEM specification
• Differential drain plug seal washer × 1 — Use OEM specification
• Rear hub axle nut × 1 — Use OEM specification - one-time use

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks in front of front wheels
3. Verify vehicle is in Park mode and 12V system is OFF (not in standby)
4. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
5. Raise rear of vehicle using floor jack at designated rear lift points
6. Support vehicle with jack stands at manufacturer-specified support points on chassis rails
7. Remove rear wheel on affected side completely
8. Place drain pan under rear differential
9. Take reference photos of axle shaft installation position and routing

Procedure

1. 1

   Remove rear hub axle nut
   Have an assistant apply brakes or use a pry bar through wheel studs to prevent hub rotation. Using a breaker bar and appropriate socket, remove the rear hub axle nut. This nut is one-time use and must be replaced. Remove and discard the nut.
2. 2

   Disconnect brake caliper mounting
   Remove the two brake caliper mounting bolts and carefully support the brake caliper assembly using wire or a bungee cord. Do not allow caliper to hang by the brake hose. Do not disconnect the brake line unless replacing the caliper.
3. 3

   Remove brake rotor
   If rotor is stuck to hub, use penetrating oil on the hub face and tap with a dead blow hammer to break corrosion seal. Remove the brake rotor completely to access the hub assembly.
4. 4

   Disconnect rear suspension lower control arm
   Locate the rear lower control arm connection point at the knuckle. Remove the bolt securing the lower control arm to the rear knuckle. Use a pry bar to separate the control arm from knuckle if necessary. Allow the suspension to drop to create clearance for axle removal.
5. 5

   Drain rear differential fluid
   Locate the rear differential drain plug on the bottom of the differential housing. Place drain pan underneath. Remove drain plug and allow approximately 2 quarts of 75W-90 GL-5 gear oil to drain completely. Inspect drain plug seal washer and replace if damaged.
   ⚠Gear oil may be warm. Allow to drain for at least 5 minutes to ensure complete drainage.
6. 6

   Separate outer CV joint from hub
   Push the outer end of the axle shaft inward through the wheel hub assembly. If the splines are tight, use a brass drift and hammer to tap the axle shaft through the hub. The outer CV joint should now be free from the hub bearing assembly.
7. 7

   Remove inner CV joint from differential
   Position pry bar between the inner CV joint housing and the differential case. Apply firm, steady pressure to disengage the axle shaft retaining circlip from the differential side gear. The axle shaft should pop free with a distinct release. Alternatively, use an axle puller tool if available. Pull the entire axle shaft assembly out from under the vehicle.
8. 8

   Inspect differential seal and side gear
   With axle removed, inspect the differential output seal for damage, leaking, or wear. Check the side gear splines inside the differential for damage or excessive wear. If seal shows any leakage or damage, it should be replaced before installing the new axle shaft.
9. 9

   Prepare new axle shaft
   Remove new axle shaft from packaging and inspect for any shipping damage. Verify the new retaining circlip is properly seated in the groove on the inner CV joint. Lightly lubricate the differential seal contact area on the inner CV joint housing with clean gear oil.
10. 10

    Install new axle shaft into differential
    Carefully align the inner CV joint splines with the differential side gear. Push the axle shaft firmly into the differential until the retaining circlip audibly clicks into place. Tug outward on the axle shaft to verify it is fully locked into the side gear and will not pull out.
11. 11

    Install outer CV joint into hub
    Guide the outer CV joint splines through the wheel hub bearing assembly. Push the axle shaft fully through until the splines are fully engaged and protrude through the hub face sufficiently for nut installation.
12. 12

    Reconnect rear suspension lower control arm
    Lift the lower control arm back into position on the rear knuckle. Install the control arm bolt and hand-tighten. Note: Final torque should be applied with vehicle at normal ride height per manufacturer specifications.
13. 13

    Refill rear differential
    Reinstall the rear differential drain plug with new seal washer. Using a gear oil pump or fluid transfer syringe, add approximately 2.0 quarts of 75W-90 GL-5 gear oil through the differential fill port until fluid reaches the bottom of the fill hole and begins to seep out. Install fill plug.
14. 14

    Install new rear hub axle nut
    Install the new rear hub axle nut onto the axle shaft threads. Hand-thread the nut fully. Have an assistant apply brakes or use the wheel stud pry bar method to prevent hub rotation. Torque the hub axle nut to manufacturer specification. Since no torque specification is provided in database, consult Rivian service documentation for proper torque value (typically 150-200 ft-lbs for EV applications).
15. 15

    Reinstall brake components
    Reinstall the brake rotor onto the hub. Position the brake caliper over the rotor and install the two caliper mounting bolts. Torque bolts to specification per Rivian service manual.

Reassembly

1. Reinstall rear wheel and hand-tighten lug nuts
2. Lower vehicle until tire just touches ground
3. Torque wheel lug nuts to specification in a star pattern
4. Completely lower vehicle and remove jack stands
5. Torque suspension control arm fasteners to specification with vehicle at normal ride height
6. Check rear differential fluid level after 24 hours and top off if necessary

Verification

• Start vehicle and verify no warning lights on instrument cluster related to drivetrain or ABS
• Test drive vehicle at low speed (under 15 mph) in a safe area and listen for any clicking, popping, or grinding noises from the rear axle
• Perform figure-eight turning maneuvers in both directions to load the CV joints and verify smooth operation
• Inspect differential drain and fill plugs for any leakage after test drive
• Verify proper AWD engagement by monitoring drive mode indicators during acceleration
• Perform final visual inspection of axle shaft installation and ensure all fasteners are tight
• Re-check differential fluid level after first 50 miles of driving

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