This procedure covers the replacement of the outer CV boot on a 2025 Rivian EDV 500 Dual Motor AWD electric delivery van, requiring axle shaft removal and disassembly.

Warnings

Tools required

Parts

• Outer CV boot kit (includes boot, clamps, and grease) × 1 — Use OEM specification
• Axle nut × 1 — Use OEM specification - single-use component
• Split pin/cotter pin × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 0.5 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen lug nuts on the wheel with the CV boot being replaced (do not remove)
4. Loosen the 32mm axle nut while vehicle is on ground (requires significant force)
5. Raise vehicle with floor jack at appropriate jacking point
6. Support vehicle securely on jack stands rated for vehicle weight
7. Remove wheel and tire assembly
8. Place drain pan under differential area to catch any fluid

Procedure

1. 1

   Remove axle nut and wheel speed sensor
   Fully remove the 32mm axle nut that was previously loosened. Locate and disconnect the wheel speed sensor electrical connector. Remove the wheel speed sensor mounting bolt and carefully extract the sensor from the knuckle to prevent damage to the sensor tip.
2. 2

   Separate lower control arm from knuckle
   Remove the bolts securing the lower ball joint to the steering knuckle. Use a ball joint separator tool or pickle fork to separate the ball joint from the knuckle if necessary. Be careful not to damage the ball joint boot if reusing components.
3. 3

   Disconnect outer tie rod end
   Remove the castle nut securing the outer tie rod end to the steering knuckle. Remove the cotter pin first. Use a tie rod separator or ball joint separator to disconnect the tie rod end from the knuckle. Do not hammer directly on threaded components.
4. 4

   Support and remove brake caliper bracket
   Remove the brake caliper mounting bolts and carefully support the caliper assembly with wire or a bungee cord to prevent strain on the brake hose. Do not let the caliper hang by the brake line. Remove the caliper bracket bolts and remove the bracket from the knuckle.
5. 5

   Remove axle shaft from hub
   Pull the steering knuckle assembly outward while pushing the axle shaft through the hub bearing. If the shaft is stuck, use a soft face hammer to tap on the end of the shaft. Be careful not to damage the ABS tone ring or hub bearing during removal.
6. 6

   Remove axle shaft from differential
   Use a pry bar positioned between the inner CV joint and differential housing to carefully pry the axle shaft from the differential. Apply steady, even pressure. The shaft should release with a distinct pop when the C-clip or retaining ring disengages. Some differential fluid may drain out - this is normal.
7. 7

   Remove damaged outer CV boot
   Place the axle shaft in a secure vise or workbench. Use side cutters or CV boot clamp pliers to remove the boot clamps from both ends of the outer boot. Slide the damaged boot off the CV joint and shaft. Wipe away old grease with shop rags and inspect the CV joint for damage.
8. 8

   Inspect and clean outer CV joint
   Carefully inspect the outer CV joint for wear, pitting, or damage to the ball bearings and races. Rotate the joint through its full range of motion checking for roughness or binding. If the joint is damaged, the entire axle shaft must be replaced. Clean all old grease from the joint and shaft using shop rags and degreaser if necessary.
9. 9

   Install new CV boot and pack with grease
   Slide the new CV boot onto the axle shaft with the small clamp in position. Pack the CV joint with the grease provided in the boot kit, ensuring grease fills all voids in the joint. The joint should contain the entire packet of grease provided. Position the boot over the CV joint and ensure it seats properly in both grooves.
10. 10

    Secure CV boot clamps
    Position the small clamp in the shaft groove and tighten using CV boot clamp pliers until secure. Ensure the boot is not twisted. Equalize air pressure in the boot by carefully lifting the large end slightly. Position the large clamp in the CV joint groove and tighten securely. Verify both clamps are properly seated and tight.
11. 11

    Reinstall axle shaft into differential
    Clean the differential splines and apply a thin coat of gear oil to the splines. Align the axle shaft with the differential opening and push firmly until the retaining ring or C-clip engages with a distinct click. Pull on the shaft to verify it is fully seated and locked in place.
12. 12

    Install axle shaft through hub bearing
    Guide the outer CV joint through the hub bearing while pulling the knuckle outward. Ensure the splines align properly and the shaft seats fully through the hub. Install the new axle nut finger-tight to hold the shaft in position during reassembly.

Reassembly

1. Reinstall the brake caliper bracket and torque mounting bolts to specification
2. Reinstall the brake caliper and torque caliper bolts to specification
3. Reconnect the outer tie rod end to the steering knuckle and install new cotter pin
4. Reconnect the lower ball joint to the steering knuckle and torque bolts to specification
5. Reinstall the wheel speed sensor and connect the electrical connector
6. Install wheel and tire assembly, hand-tighten lug nuts
7. Lower vehicle until tire just touches ground
8. Torque axle nut to specification while applying brakes (refer to service manual for exact torque value)
9. Install axle nut cotter pin or locking mechanism as designed
10. Torque wheel lug nuts to specification in a star pattern
11. Lower vehicle completely and remove jack stands
12. Check and top off differential fluid if necessary through fill plug

Verification

• Test drive vehicle at various speeds and listen for clicking, popping, or grinding noises from the CV joint area
• Turn steering wheel through full lock-to-lock motion while driving slowly to verify CV joint operates smoothly
• Inspect the new CV boot for proper seating and verify clamps are secure
• Check for any differential fluid leaks around the axle seal area
• Verify wheel speed sensor is functioning properly by checking for ABS warning lights on dash
• Re-torque axle nut after 50-100 miles of driving
• Inspect CV boot again after 500 miles for any signs of movement or leaking grease

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