Replace the inner CV boot on a 2025 Rivian EDV 500 dual motor AWD, requiring axle removal and disassembly of the inner CV joint to install a new boot and grease.

Warnings

Tools required

Parts

• Inner CV boot kit with clamps × 1 — Use OEM specification
• CV joint grease (included in kit or separate) × 1 — Use OEM specification
• Axle nut (one-time use) × 1 — Use OEM specification
• Circlip/snap ring (if damaged) × 1 — Use OEM specification

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 5 minutes
3. Raise and support vehicle on jack stands at frame lift points rated for electric vehicle weight
4. Remove wheel and tire assembly from affected side
5. Place drain pan under front differential
6. Mark axle shaft orientation to differential for reassembly reference

Procedure

1. 1

   Remove axle nut
   Have an assistant apply brakes or use a pry bar through wheel studs to prevent rotation. Remove and discard the 32mm front axle nut. This is a one-time use fastener and must be replaced.
2. 2

   Disconnect lower control arm
   Remove the bolt connecting the lower control arm ball joint to the steering knuckle. Use a ball joint separator to disconnect the joint if it does not release easily. Support the lower control arm to prevent it from dropping.
3. 3

   Separate axle from hub
   Push the axle shaft inward through the wheel hub. If the axle is stuck, use a soft-faced hammer to gently tap the end of the shaft while pulling the knuckle outward. Do not damage the threads or splines.
4. 4

   Remove inner axle from differential
   Position drain pan under the differential. Using a pry bar positioned against the inner CV joint housing and differential case, carefully pry the axle assembly out of the differential. Expect approximately 1.5 quarts of gear oil to drain. If axle is difficult to remove, use a slide hammer with appropriate adapter.
5. 5

   Secure and clean axle shaft
   Place the axle shaft on a clean workbench with the inner CV joint accessible. Clean the entire axle shaft and CV joint area with a wire brush and degreaser. Remove all old grease and debris.
6. 6

   Remove old inner CV boot
   Cut and remove both clamps from the inner CV boot using side cutters. Slide the old boot toward the center of the axle shaft. Mark the position of the inner CV joint housing on the axle shaft for reassembly reference.
7. 7

   Disassemble inner CV joint
   Remove the circlip/snap ring securing the inner CV joint housing to the axle shaft using snap ring pliers. Slide the joint housing off the tripod assembly. Remove all old grease from the housing and tripod. Mark the tripod orientation on the shaft before removal.
8. 8

   Remove tripod assembly
   Remove the second circlip that retains the tripod assembly on the axle shaft. Carefully slide the tripod assembly off the shaft. Inspect the tripod bearings and rollers for wear or damage. If damaged, the entire axle shaft may require replacement.
9. 9

   Install new inner CV boot
   Slide the new inner CV boot onto the axle shaft from the inner end, positioning the small end clamp on the boot groove on the shaft. Ensure the boot is not twisted. Install the small clamp but do not fully tighten yet.
10. 10

    Reinstall tripod assembly
    Reinstall the tripod assembly onto the axle shaft in the original orientation as marked. Install the retaining circlip and ensure it is fully seated in its groove. The tripod should not slide off the shaft once the circlip is installed.
11. 11

    Pack CV joint with grease and reassemble
    Pack half of the supplied CV grease into the inner CV joint housing. Reinstall the housing over the tripod assembly, aligning with the marks made during disassembly. Pack the remaining grease around the tripod and inside the boot. Install the housing retaining circlip.
12. 12

    Secure CV boot clamps
    Position the large end of the CV boot into the groove on the joint housing. Compress or extend the boot to the correct length to avoid over-compression or stretching during suspension travel. Tighten the small clamp using CV boot clamp pliers, then install and tighten the large clamp. Ensure both clamps are secure and the boot is not twisted.
13. 13

    Reinstall axle into differential
    Clean the differential output splines with a clean rag. Align the axle shaft with the differential opening and push firmly until the circlip on the axle engages. You should hear and feel a click when properly seated. Pull on the inner CV joint housing to verify the axle is locked in place.
14. 14

    Reinstall axle into hub and reconnect suspension
    Guide the outer end of the axle through the wheel hub, ensuring splines align. Reconnect the lower control arm ball joint to the steering knuckle and install the retaining bolt. Install a new axle nut and tighten by hand.
15. 15

    Torque axle nut and refill differential
    With vehicle still raised and brakes applied, torque the new front axle nut to manufacturer specification (torque value not available in database - consult service manual). Refill the front differential with 1.5 quarts of 75W-90 GL-5 gear oil through the fill plug. Reinstall wheel and tire assembly.

Reassembly

1. Torque wheel lug nuts to specification in a star pattern
2. Lower vehicle to ground
3. Reconnect 12V battery negative terminal
4. Check differential fluid level after test drive and top off if necessary

Verification

• Start vehicle and verify no warning lights are displayed related to drivetrain or traction systems
• Test drive vehicle at low speed and listen for clicking or popping noises from the CV joint during turns
• Perform full lock turns in both directions to verify CV joint operation
• Inspect for gear oil leaks around the inner CV boot and differential seal
• Verify no grease is leaking from CV boot clamps
• Check that all suspension components are properly secured and torqued

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