Replace the differential cover gasket on a 2025 Rivian EDV 500, including draining and refilling the differential fluid to prevent leaks.

Warnings

Tools required

Parts

• Differential cover gasket (front or rear as applicable) × 1 — Use OEM specification
• Differential cover bolts (if reusable bolts show wear) × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Place vehicle on a level surface and engage parking brake
2. Disable high voltage system according to Rivian service procedures
3. Raise vehicle on lift or jack stands to provide adequate working clearance under differential
4. Allow differential to cool to ambient temperature if vehicle was recently operated
5. Identify which differential (front or rear) requires gasket replacement
6. Position drain pan beneath differential cover
7. Clean exterior of differential cover and surrounding area to prevent contamination

Procedure

1. 1

   Drain differential fluid
   Locate the differential cover bolts on the rear of the differential housing. Loosen all cover bolts approximately 2-3 turns, but do not remove. Starting from the top bolts and working down, carefully remove the upper bolts first to allow fluid to drain in a controlled manner into the drain pan. Once fluid flow slows, remove remaining bolts and carefully pry the cover away from the housing.
2. 2

   Remove differential cover
   Fully remove the differential cover and set aside. Allow all remaining fluid to drain completely from the housing. Inspect the drained fluid for metal particles or debris that might indicate internal wear. Excessive debris may require further inspection of differential internals.
3. 3

   Clean differential cover mating surface
   Use a plastic gasket scraper to carefully remove all old gasket material from the differential cover. Avoid using metal scrapers that could gouge the aluminum surface. Clean the cover thoroughly with brake cleaner and wipe dry with shop towels. Inspect the cover for cracks, warping, or damage.
4. 4

   Clean differential housing mating surface
   Carefully scrape all old gasket material from the differential housing mating surface using a plastic scraper. Take care not to allow debris to fall into the open differential. Use brake cleaner and shop towels to remove all residue. The mating surface must be completely clean and dry for proper gasket sealing.
5. 5

   Inspect differential housing interior
   With the cover removed, visually inspect the interior of the differential housing for any obvious damage, excessive wear, or loose components. Check the condition of the ring gear teeth. If any abnormalities are found, further diagnosis may be required before proceeding.
6. 6

   Install new gasket
   Position the new differential cover gasket onto the cover or housing according to manufacturer instructions. Some gaskets may have an adhesive backing or may require a thin bead of RTV sealant on one side. Ensure the gasket is properly aligned with all bolt holes and sits flush against the mating surface.
7. 7

   Install differential cover
   Carefully position the differential cover with gasket onto the housing, ensuring the gasket remains properly aligned. Start all cover bolts by hand to prevent cross-threading. Once all bolts are hand-started, tighten them in a crisscross pattern to ensure even gasket compression. Since no specific torque values are provided in the database, tighten bolts gradually and evenly to approximately 18-22 ft-lbs (typical for this application), or consult Rivian service documentation for exact specifications.
8. 8

   Refill differential with gear oil
   Locate the differential fill plug on the side of the housing. Remove the fill plug to allow air to escape during filling. Using a fluid pump or funnel with hose, add the appropriate quantity of 75W-90 GL-5 gear oil (1.5 quarts for front differential, 2.0 quarts for rear differential). Fill until fluid reaches the bottom of the fill plug hole. Reinstall and tighten fill plug.
9. 9

   Check for leaks
   Wipe down the differential cover and surrounding area to remove any spilled fluid. Inspect all around the cover gasket for signs of fluid seepage. If any leaks are visible, the cover bolts may need slight additional tightening or the cover may need to be removed and gasket reinstalled.
10. 10

    Clean work area and lower vehicle
    Remove drain pan and dispose of used gear oil properly at a recycling facility. Clean any spilled fluid from under the vehicle. Lower vehicle from lift or jack stands back to ground level.

Reassembly

1. Torque all fasteners in proper sequence if specific values become available from manufacturer
2. Ensure fill plug is securely tightened to prevent leaks
3. Re-enable high voltage system according to Rivian procedures
4. Dispose of used gear oil in accordance with local environmental regulations

Verification

• Start vehicle and allow to run briefly, then check differential cover area for any fluid leaks
• Take vehicle for a short test drive (1-2 miles) with moderate acceleration and turning
• Re-inspect differential cover gasket area after test drive for any signs of seepage
• Check differential fluid level at fill plug after test drive and top off if necessary
• Monitor differential cover area over the next few days of driving to ensure gasket seal remains intact

More procedures for this vehicle