This procedure covers the removal and replacement of a front CV axle on a 2025 Rivian EDV 500 commercial delivery van with dual motor AWD drivetrain.

Warnings

Tools required

Parts

• Front CV axle assembly × 1 — Use OEM Rivian specification
• CV axle hub nut × 1 — Use OEM specification - one-time use
• Lower control arm ball joint nut (if damaged) × 1 — Use OEM specification
• Differential output shaft seal × 1 — Use OEM specification
• CV axle retaining circlip × 1 — Usually included with new axle

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal and wait 10 minutes for system capacitors to discharge
3. If equipped with air suspension, use service mode to raise suspension to maximum height for clearance
4. Loosen front wheel lug nuts while vehicle is on ground (1/4 turn)
5. Loosen but do not remove the front hub axle nut while vehicle is on ground with wheels chocked and brakes applied
6. Raise front of vehicle and support on jack stands at manufacturer-specified lift points
7. Remove front wheel on side being serviced
8. Place drain pan under front differential on side being serviced

Procedure

1. 1

   Remove hub nut and brake caliper
   Fully remove the previously loosened front hub axle nut and set aside (this is a one-time use fastener and must be replaced). Remove the two brake caliper mounting bolts and carefully support the caliper with wire or a bungee cord without allowing strain on the brake hose. Do not let caliper hang by the brake line.
2. 2

   Remove brake rotor
   Remove the brake rotor from the hub. If rotor is stuck due to corrosion, use penetrating oil and tap gently with plastic mallet around the hat section. Do not strike rotor friction surface.
3. 3

   Disconnect ABS wheel speed sensor
   Locate the ABS wheel speed sensor connector near the strut tower or frame rail. Disconnect the electrical connector and carefully remove any routing clips securing the sensor harness to prevent damage during axle removal.
4. 4

   Separate lower ball joint
   Remove the lower control arm ball joint castle nut or retention nut. Use a ball joint separator tool or pickle fork to separate the ball joint from the steering knuckle. Apply penetrating oil if joint is difficult to separate. Note the orientation and position of any spacers or washers.
5. 5

   Release outer CV joint from hub
   Push the CV axle shaft through the wheel hub bearing. If the axle is seized in the hub bearing, use a soft-face mallet to tap the end of the axle shaft, or use aCV axle puller tool to press it out from behind the hub. Be careful not to damage the hub bearing or ABS reluctor ring.
6. 6

   Support the drive unit and knuckle assembly
   Position a jack or support under the steering knuckle assembly to control its movement once the CV axle is fully disconnected. This prevents damage to brake lines, ABS wiring, and suspension components.
7. 7

   Remove inner CV joint from differential
   Position the drain pan directly under the differential output shaft. Using a large pry bar positioned against the inner CV joint housing and the differential case, carefully pry the inner CV joint out of the differential. The axle is retained by a circlip and will release with firm pressure. Expect differential fluid to drain. Alternatively, use a slide hammer with appropriate adapter if available.
8. 8

   Remove CV axle assembly
   Carefully maneuver the complete CV axle assembly out from between the steering knuckle and differential. Route it out from under the vehicle, being careful not to damage CV boots, ABS wiring, or brake lines during removal.
9. 9

   Inspect and replace differential seal
   With the CV axle removed, inspect the differential output shaft seal for damage, leaking, or wear. Using a seal puller or pick, carefully remove the old seal. Clean the seal bore thoroughly with a wire brush and clean rag. Install the new differential seal using a seal driver or appropriately sized socket, driving it in squarely until fully seated.
10. 10

    Prepare new CV axle
    Unpack the new CV axle assembly and verify it matches the original in length and spline configuration. Ensure a new circlip is installed on the inner CV joint splines (typically pre-installed on new axles). Inspect both CV boots for damage that may have occurred during shipping.
11. 11

    Install new CV axle into differential
    Apply a thin coat of 75W-90 GL-5 gear oil to the inner CV joint splines. Align the inner CV joint with the differential output shaft and push firmly until the circlip snaps into the groove with an audible click. Pull outward on the inner joint to verify it is securely retained and will not pull out of the differential.
12. 12

    Install outer CV joint into hub
    Guide the outer CV joint shaft through the wheel hub bearing, ensuring proper alignment. Push the shaft through until it is fully seated and the splines engage. Do not force or hammer the shaft through the bearing as this can cause damage.
13. 13

    Reconnect lower ball joint
    Align the lower control arm ball joint stud with the steering knuckle. Install the ball joint nut and tighten to proper specification. If required by design, install a new cotter pin or lock the castle nut properly. Apply medium-strength thread locker if specified.
14. 14

    Install new hub nut and secure
    Install the NEW hub axle nut onto the CV axle shaft (do not reuse the old nut). Thread it on by hand initially. Have an assistant apply the brakes or use a suitable method to prevent hub rotation, then torque the hub nut to manufacturer specification. This typically requires very high torque (200+ ft-lbs on most vehicles). Stake or lock the nut per manufacturer requirements.
15. 15

    Reinstall brake components and refill differential
    Reinstall the brake rotor and caliper assembly, torquing caliper bolts to specification. Reconnect the ABS wheel speed sensor and secure all wiring clips. Remove the drain pan and refill the front differential with 75W-90 GL-5 gear oil to the proper level (1.5 qt capacity) through the fill port until fluid reaches the fill hole level.

Reassembly

1. Reinstall the wheel and hand-tighten lug nuts in a star pattern
2. Lower vehicle until tire just contacts ground but weight is still on jack stands
3. Torque wheel lug nuts to manufacturer specification in star pattern
4. Fully lower vehicle and remove jack stands
5. Reconnect 12V battery negative terminal
6. If air suspension was placed in service mode, exit service mode through vehicle interface or scan tool
7. Pump brake pedal several times to ensure proper brake caliper piston position before moving vehicle

Verification

• Start vehicle and verify no warning lights related to ABS, traction control, or drivetrain systems
• Perform a short test drive at low speed in a safe area, checking for vibration, noise, or clicking from the CV axle
• Test full steering lock left and right while moving slowly to ensure CV joint operates smoothly through full range
• Check for any differential fluid leaks around the inner CV joint area after test drive
• Verify proper AWD engagement if vehicle has selectable modes
• Re-torque wheel lug nuts after 50-100 miles of driving
• Monitor for any unusual noises or vibrations during the first several hundred miles of operation

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