This procedure covers the removal and replacement of both positive and negative high-voltage battery cables on the 2025 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• Positive high-voltage battery cable assembly × 1 — Use OEM specification
• Negative high-voltage battery cable assembly × 1 — Use OEM specification
• HV cable terminal seals/boots × 4 — Use OEM specification
• Cable retention clips × 6 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off vehicle completely and remove key fob from cabin area (minimum 15 feet away)
3. Verify vehicle has been sitting idle for at least 30 minutes to allow components to cool
4. Open rear cargo area and access panels to expose battery compartment
5. Remove underbody panels to access high-voltage junction box and motor connections
6. Document all cable routing with photographs from multiple angles
7. Verify high-voltage insulated gloves are intact with no damage, tears, or punctures

Procedure

1. 1

   Access and open battery service disconnect
   Locate the manual service disconnect (MSD) in the battery pack area beneath rear cargo floor. Using the Rivian service disconnect tool, rotate the MSD handle counterclockwise to the OFF position. Remove the MSD completely from its housing and store in a secure location away from vehicle to prevent accidental reconnection.
2. 2

   Wait for capacitor discharge and verify zero voltage
   Wait minimum 10 minutes to allow all high-voltage capacitors in the system to fully discharge. After waiting period, don high-voltage insulated gloves. Using a calibrated digital multimeter set to DC voltage, verify 0 volts between positive and negative HV terminals at the battery pack, at the front motor junction, and at the rear motor junction. Record voltage readings. Do not proceed if any voltage above 0V is detected.
3. 3

   Remove front motor high-voltage connections
   Locate the front motor high-voltage junction box in the front subframe area. Remove the orange safety cover from the HV connector. Disconnect the positive and negative cable connectors from the front motor terminals by releasing the locking tabs and pulling straight back. Support cables to prevent strain on connections. Mark cables with tape indicating 'FRONT' for reassembly.
4. 4

   Remove rear motor high-voltage connections
   Access the rear motor high-voltage junction box beneath the battery pack. Remove the orange safety cover. Release locking mechanisms and disconnect both positive and negative cables from rear motor terminals. Support cable weight and mark cables with 'REAR' designation.
5. 5

   Release cable routing clips and supports
   Working from motors toward battery, identify and release all cable retention clips, P-clips, and routing guides securing HV cables to vehicle chassis. Count and document number and position of each clip type. Carefully release cables from routing channels, noting any vibration dampeners or separation devices between positive and negative cables.
6. 6

   Disconnect cables from battery pack terminals
   Access battery pack HV terminals inside battery enclosure. Remove terminal covers and safety locks. Disconnect negative cable first, then positive cable from battery pack main terminals. Remove any additional ground straps or auxiliary connections. Support cable assemblies during removal to prevent damage to nearby components.
7. 7

   Remove battery cable assemblies
   Carefully extract both positive and negative cable assemblies from vehicle following documented routing paths. Use cable lift support if needed due to weight. Inspect routing channels and grommets for damage. Clean any debris from cable routing areas.
8. 8

   Inspect terminals and connection points
   Examine all battery terminals, motor terminals, and junction points for signs of arcing, corrosion, discoloration, or damage. Clean terminals using battery terminal cleaner if corrosion is present. Inspect terminal threads and ensure they are clean and undamaged. Replace any damaged terminals or connection hardware.
9. 9

   Route new positive cable assembly
   Following documented routing path and photographs, route new positive (orange-marked) cable assembly from battery pack to both motor connections. Ensure cable follows original path exactly, maintaining proper clearances from moving parts, sharp edges, and heat sources. Do not force cables into position.
10. 10

    Route new negative cable assembly
    Route new negative (black-marked) cable assembly following original path from battery pack to motor connections. Maintain separation from positive cable as originally configured. Verify cables do not contact suspension components, steering components, or brake lines throughout full range of motion.
11. 11

    Secure cables with retention clips
    Install all cable retention clips, P-clips, and routing guides in their original positions. Ensure clips are fully seated and secure. Verify proper clip engagement - cables should be held firmly but not crushed or deformed. Install all vibration dampeners and cable separators.
12. 12

    Connect cables to battery pack
    Connect positive cable to positive battery terminal first, then negative cable to negative terminal. Apply light coating of dielectric grease to terminals before connection. Hand-tighten connections, then torque to manufacturer specification (value not available - consult Rivian service manual). Install new terminal seals and safety covers. Verify connections are secure with no movement.
13. 13

    Connect rear motor cables
    Connect positive and negative cables to rear motor HV junction box. Ensure connectors are fully seated with locking tabs engaged. Install new connector seals. Verify no gaps between connector bodies and junction box. Install orange safety cover and secure.
14. 14

    Connect front motor cables
    Connect positive and negative cables to front motor HV junction box following same procedure as rear motor. Verify full seating of connectors and proper lock engagement. Install new connector seals and orange safety cover.
15. 15

    Perform pre-energization inspection
    With MSD still removed, perform complete visual inspection of all HV cable connections, routing, and retention. Verify no tools or foreign objects are in battery compartment or near HV components. Check that all safety covers are installed. Verify cable routing allows full suspension travel without interference. Reinstall all underbody panels and access covers except those needed to access MSD.

Reassembly

1. Perform final visual inspection of entire HV cable system from battery to both motors
2. Verify all cable retention clips are secure and cables follow original routing paths exactly
3. Ensure all orange safety covers are installed on HV junction boxes and battery terminals
4. Reinstall manual service disconnect (MSD) into battery pack housing and rotate clockwise to ON position
5. Reinstall all underbody panels, access covers, and cargo floor panels
6. Clear any service mode settings or fault codes using Rivian diagnostic tool if applicable

Verification

• Using Rivian diagnostic software, verify no high-voltage isolation faults or system errors are present
• Check battery management system reports proper voltage readings across all cells
• Perform power-up sequence and verify READY indicator illuminates without warnings
• Test both front and rear motor operation by driving vehicle slowly in controlled area
• Verify no unusual sounds, smells, or warnings during initial test drive
• Monitor HV system voltage and current during acceleration and regenerative braking
• Perform final inspection under vehicle to verify no cable contact or rubbing after test drive
• Document repair in vehicle service history with date, mileage, and part numbers used

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