CV Axle - Rear

This procedure covers the removal and replacement of the rear CV axle assembly on a 2025 Rivian EDV 500 dual motor electric delivery van.

Warnings

Tools required

Parts

• Rear CV axle assembly × 1 — Use OEM Rivian specification
• CV axle retaining circlip × 1 — Usually included with CV axle
• Hub nut × 1 — Use OEM specification, one-time use
• Differential seal (if damaged) × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks on front wheels
3. Using Rivian service interface or compatible scan tool, enable Service Mode to disable high voltage systems
4. Disconnect 12V battery negative terminal and wait 5 minutes
5. Loosen rear wheel lug nuts while vehicle is on ground
6. Raise rear of vehicle and support on manufacturer-specified jack stand points
7. Remove rear wheel on affected side
8. Position drain pan under rear differential on the side being serviced

Procedure

1. 1

   Remove wheel speed sensor
   Disconnect the wheel speed sensor electrical connector at the rear knuckle. Remove the sensor mounting bolt and carefully extract the sensor from the knuckle. Secure sensor away from work area to prevent damage.
2. 2

   Remove hub retaining nut
   Have an assistant apply brakes or use a suitable holding tool to prevent wheel hub rotation. Using a 30mm socket and breaker bar, remove the CV axle hub retaining nut. This nut is one-time use and must be replaced. Mark the position of any washers for reassembly.
3. 3

   Disconnect lower control arm
   Remove the bolt securing the lower control arm to the rear knuckle. Support the control arm to prevent it from dropping. This will provide clearance for CV axle removal.
4. 4

   Disconnect parking brake cable
   If equipped with electric parking brake actuator on this axle, disconnect the electrical connector. Release any cable routing clips or brackets that may interfere with axle removal.
5. 5

   Separate CV axle from wheel hub
   Push the CV axle shaft inward through the wheel hub. If the axle is stuck in the hub splines, use a brass drift and soft-faced mallet to tap the end of the axle shaft while pulling the knuckle assembly outward. Do not strike the threaded portion of the axle shaft.
6. 6

   Support CV axle
   Support the CV axle with a bungee cord or wire to prevent it from hanging by the inner joint once separated from the differential. Position drain pan directly under the differential stub shaft.
7. 7

   Remove CV axle from differential
   Using a pry bar positioned against the differential housing and the CV axle inner joint housing, apply steady outward pressure to release the retaining circlip from the differential stub shaft. Alternatively, use a CV axle puller or slide hammer attached to the inner joint. Once the circlip releases, pull the axle straight out of the differential. Gear oil will drain from the differential opening.
8. 8

   Remove CV axle assembly
   Carefully maneuver the CV axle assembly out of the vehicle, taking care not to damage the CV boots on surrounding components. Inspect the removed axle for torn boots, damaged joints, or excessive play.
9. 9

   Inspect differential seal and housing
   Inspect the differential seal for damage or leakage. If seal shows signs of wear or was damaged during axle removal, replace it now. Clean the differential stub shaft splines and sealing surface with a wire brush and lint-free cloth.
10. 10

    Prepare new CV axle
    Remove the new CV axle from packaging and verify it matches the removed unit. Ensure the new retaining circlip is properly seated in the groove on the inner CV joint. Lightly lubricate the differential seal contact area on the new axle with clean gear oil.
11. 11

    Install CV axle into differential
    Align the splines of the inner CV joint with the differential stub shaft. Push the axle firmly into the differential until the retaining circlip seats with an audible click. Verify the axle is fully engaged by attempting to pull it outward - it should not come out.
12. 12

    Install CV axle into wheel hub
    Guide the outer CV axle shaft through the wheel hub bearing, ensuring proper spline alignment. Push the shaft fully through the hub until it protrudes sufficiently for nut installation. Do not force or hammer the shaft through the bearing.
13. 13

    Reconnect suspension components
    Reconnect the lower control arm to the rear knuckle and install the mounting bolt. Reconnect the parking brake cable and any electrical connectors that were disconnected. Reinstall the wheel speed sensor into the knuckle and secure with mounting bolt.
14. 14

    Install new hub retaining nut
    Install the new hub retaining nut (and washer if equipped) onto the CV axle shaft. Hand-thread the nut to prevent cross-threading. Have an assistant apply brakes or use a holding tool, then torque the hub nut to manufacturer specification. Since no torque specification is provided in the database, consult the vehicle service manual for the correct value (typically 150-200 ft-lb for this class of vehicle).
15. 15

    Refill rear differential
    Add 75W-90 GL-5 gear oil to the rear differential through the fill port until oil begins to drip from the fill hole (approximately 2.0 quarts). Install and tighten the fill plug. Wipe away any spilled oil.

Reassembly

1. Reinstall the rear wheel and hand-tighten lug nuts
2. Lower vehicle until tire just contacts ground, then torque lug nuts to specification in star pattern
3. Fully lower vehicle and remove jack stands
4. Reconnect 12V battery negative terminal
5. Exit Service Mode using Rivian service interface
6. Verify all warning lights extinguish and no new fault codes are present

Verification

• Start vehicle and verify no unusual noises from rear differential or CV axle
• Test drive vehicle in a safe area, checking for vibration, clicking noises during turns, or binding sensations
• Verify wheel speed sensor is functioning properly (no ABS warning lights)
• After test drive, inspect CV axle boots for damage and check for gear oil leaks at differential seal
• Recheck rear differential fluid level after test drive and top off if necessary
• Verify parking brake operates correctly if cable was disconnected

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