drivetrain

CV Axles - Front Pair

for 2025 Rivian EDV 500 Dual Motor AWD (EDV) · AWD

Difficulty

Advanced

Time

5.2 h

Tools

Steps

🤖AI-generated, not yet human-verified. This walkthrough was produced by AI and may contain errors. Treat it as a guide, cross-check every step and torque value against the manufacturer's service manual, and stop if anything looks unsafe. This is a moderate-risk job — take extra care.

This procedure covers the removal and replacement of both front CV axles on the 2025 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

⚠️This vehicle weighs over 6,000 lbs. Ensure jack stands are rated appropriately and positioned on designated lift points only.

⚠️The high voltage battery system must be disabled before beginning work. Follow Rivian service procedures for HV isolation.

⚠The front differential is integrated with the front drive unit. Do not disconnect electrical connections unless necessary.

⚠New axle hub nuts must be installed. Do not reuse old hub nuts as they are torque-to-yield.

ℹ️Some differential fluid loss is expected when removing CV axles. Have additional fluid available to refill.

Tools required

Floor jack and jack stands rated for vehicle weightEssential

Torque wrench (50-250 ft-lb range)Essential

19mm socket and ratchetEssential

21mm socket and ratchetEssential

36mm axle nut socketEssential

Pry bar or CV axle puller toolEssential

Ball joint separator toolEssential

Breaker barEssential

Drain pan for differential fluidEssential

Slide hammer with axle adapter

Plastic mallet

Wire brush

Transmission jack or axle support

Parts

Front CV axle assembly - driver side × 1 — Use OEM specification
Front CV axle assembly - passenger side × 1 — Use OEM specification
Axle hub nut - driver side × 1 — Use OEM specification
Axle hub nut - passenger side × 1 — Use OEM specification
Front differential output seal - driver side × 1 — Use OEM specification
Front differential output seal - passenger side × 1 — Use OEM specification
Lower control arm ball joint nut (if necessary) × 2 — Use OEM specification

Fluids

75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

Park vehicle on level surface and engage parking brake
Disable the high voltage system following Rivian service manual HV isolation procedure
Disconnect 12V battery negative terminal and wait 2 minutes
Loosen both front axle hub nuts while vehicle is on the ground with wheels installed and parking brake engaged
Raise front of vehicle and support securely on jack stands at designated lift points
Remove both front wheels
Place drain pan under front differential to catch any fluid spillage

Procedure

1
Remove driver side axle hub nut
With the vehicle raised and supported, completely remove the previously loosened 36mm driver side axle hub nut. Discard the nut as it must not be reused. Apply penetrating lubricant to the axle splines if corrosion is present.
2
Disconnect driver side lower ball joint
Remove the lower control arm ball joint nut. Use a ball joint separator tool to disconnect the lower ball joint from the steering knuckle. Apply force carefully to avoid damaging the ball joint boot or knuckle threads.
3
Support driver side CV axle
Support the outer end of the CV axle to prevent it from dropping and damaging components. Use a transmission jack or have an assistant support the axle during removal.
4
Remove driver side CV axle from hub
Push the CV axle through the wheel hub assembly. If the axle is seized in the hub, use a brass drift or soft mallet to tap it through from the back side. Do not damage the wheel speed sensor or hub bearing during this process.
5
Extract driver side CV axle from differential
Using a pry bar positioned against the differential housing, carefully pry the inner CV joint out of the front differential. Apply even pressure and work the axle out gradually. If the axle is stubborn, use a slide hammer with appropriate CV axle adapter. Once the circlip disengages, the axle will release suddenly. Control the axle to prevent damage to surrounding components.
6
Inspect and replace driver side differential seal
With the axle removed, inspect the differential output shaft seal for damage or leakage. Remove the old seal using a seal puller or appropriate tool. Clean the seal bore thoroughly with a wire brush. Install the new differential output seal using a seal driver, ensuring it seats evenly and completely. Lubricate the seal lip with fresh gear oil before installing the new axle.
7
Remove passenger side axle hub nut
Completely remove the previously loosened 36mm passenger side axle hub nut. Discard the nut as it must not be reused. Apply penetrating lubricant to the axle splines if necessary.
8
Disconnect passenger side lower ball joint
Remove the lower control arm ball joint nut. Use the ball joint separator tool to disconnect the lower ball joint from the steering knuckle on the passenger side.
9
Remove passenger side CV axle from hub and differential
Support the outer end of the axle, then push the CV axle through the wheel hub assembly. Using a pry bar, carefully extract the inner CV joint from the front differential using the same technique as the driver side. Control the axle as the circlip releases.
10
Inspect and replace passenger side differential seal
Remove the old differential output shaft seal and clean the seal bore. Install the new differential output seal using a seal driver, ensuring proper seating. Lubricate the seal lip with fresh gear oil.
11
Install new driver side CV axle
Align the new driver side CV axle with the differential output shaft. Apply a thin coat of gear oil to the axle splines. Firmly push the inner CV joint into the differential until the circlip engages with a distinct click. Verify engagement by attempting to pull the axle back out. Insert the outer CV axle stub shaft through the wheel hub assembly, ensuring proper alignment with the hub splines.
12
Reconnect driver side lower ball joint and install new hub nut
Reconnect the lower control arm ball joint to the steering knuckle. Install a new ball joint nut if specified. Install the new 36mm axle hub nut on the driver side and hand tighten only at this stage.
13
Install new passenger side CV axle
Apply gear oil to the passenger side axle splines. Insert the inner CV joint into the differential until the circlip clicks into place. Verify engagement. Insert the outer stub shaft through the wheel hub assembly.
14
Reconnect passenger side lower ball joint and install new hub nut
Reconnect the passenger side lower control arm ball joint to the steering knuckle. Install the new 36mm axle hub nut and hand tighten.
15
Check and refill front differential fluid
Check the front differential fluid level through the fill plug. Add 75W-90 GL-5 gear oil as necessary to bring the level to the bottom of the fill hole. The differential capacity is 1.5 quarts, but only add what was lost during the procedure. Install the fill plug when complete.

Reassembly

Install both front wheels and hand tighten lug nuts in a star pattern
Lower vehicle until wheels just contact the ground but suspension is not fully loaded
Torque both 36mm axle hub nuts to manufacturer specification (not available in database - consult Rivian service manual)
Torque lower ball joint nuts to specification (consult Rivian service manual)
Torque wheel lug nuts to specification in a star pattern (consult Rivian service manual)
Fully lower vehicle and remove jack stands
Reconnect 12V battery negative terminal
Re-enable high voltage system following Rivian service procedures

Verification

Start vehicle and verify no warning lights related to drivetrain or ABS systems are illuminated
Perform a test drive at low speed in a safe area, checking for vibration, noise, or binding during turns
Verify smooth operation during acceleration and deceleration
Check for any differential fluid leaks around both CV axle seals after test drive
Verify proper operation of all-wheel drive system if equipped with AWD diagnostic mode
Re-check axle hub nut torque after initial test drive
Inspect wheel speed sensor operation by verifying ABS system functionality