This procedure covers draining and refilling the front differential fluid on the 2025 Rivian EDV 500 dual motor AWD electric delivery van, requiring removal of skid plates and underbody panels for access.

Warnings

Tools required

Parts

• Front differential drain plug gasket/washer × 1 — Use OEM specification
• Front differential fill plug gasket/washer × 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. Ensure vehicle is fully powered off with key fob outside the vehicle
3. Allow differential to cool if vehicle was recently driven (minimum 30 minutes)
4. Raise vehicle on lift or jack stands to provide adequate working clearance underneath
5. Verify vehicle is stable and secure before working underneath
6. Remove front skid plate and underbody panels as needed to access front differential (typically multiple Torx fasteners)
7. Clean area around differential drain and fill plugs with wire brush to prevent contamination

Procedure

1. 1

   Locate front differential service points
   Identify the front differential housing mounted between the front wheels. Locate the drain plug on the bottom of the differential housing and the fill plug on the side or upper portion of the housing. Note their positions and ensure you have adequate access to both plugs before proceeding.
2. 2

   Remove fill plug first
   Using the appropriate socket, loosen and remove the fill plug BEFORE removing the drain plug. This ensures you will be able to refill the differential after draining. If the fill plug is seized and cannot be removed, do not proceed with draining. Set the fill plug and washer aside in a clean area.
3. 3

   Position drain pan
   Place a drain pan with at least 2 quart capacity directly beneath the front differential drain plug. Position the pan to account for the initial stream of fluid which may project outward when the plug is first removed.
4. 4

   Remove drain plug and drain fluid
   Using the appropriate socket, carefully loosen the drain plug. Remove the plug completely by hand for the final turns to avoid dropping it into the drain pan. Allow the gear oil to drain completely, which may take 10-15 minutes. Inspect the drained fluid for metal particles or debris that could indicate internal wear.
5. 5

   Inspect and clean drain plug
   Examine the drain plug for damage to the threads or magnetic tip (if equipped). Clean the plug thoroughly with a lint-free rag. Check the drain plug sealing surface on the differential housing and clean any old gasket material or debris. Discard the old drain plug washer/gasket.
6. 6

   Reinstall drain plug
   Install a new drain plug washer/gasket onto the drain plug. Thread the drain plug into the differential housing by hand to avoid cross-threading. Tighten the drain plug securely using a torque wrench to manufacturer specification. Without official torque specs, tighten firmly but cautiously to avoid stripping aluminum housing threads (typical range for this application would be 25-35 ft-lb, but use careful judgment).
7. 7

   Prepare to fill differential
   Wipe the area around the fill plug hole clean. Prepare the fluid transfer pump with fresh 75W-90 GL-5 gear oil. Ensure the pump tube or nozzle can reach into the fill hole and that you have at least 1.5 quarts of fluid available.
8. 8

   Refill front differential
   Insert the pump nozzle into the fill hole and slowly add 75W-90 GL-5 gear oil. Fill until fluid begins to drip or run out of the fill hole, indicating the proper level has been reached. The front differential capacity is 1.5 quarts, but fill to the level of the fill hole rather than by volume measurement.
9. 9

   Reinstall fill plug
   Install a new fill plug washer/gasket onto the fill plug. Wipe away any excess oil from around the fill hole. Thread the fill plug into the housing by hand, then tighten securely with a torque wrench. Without official specifications, use the same careful approach as the drain plug.
10. 10

    Clean and inspect for leaks
    Wipe down the entire differential housing to remove any spilled gear oil. Inspect both the drain and fill plugs for signs of leakage. Check that both plugs are seated properly and tightened securely.

Reassembly

1. Reinstall all underbody panels and skid plates removed during preparation, ensuring all Torx fasteners are properly tightened
2. Lower vehicle to ground
3. Dispose of used gear oil at an appropriate recycling facility according to local regulations
4. Clean all tools and work area

Verification

• Start vehicle and allow front motor to operate briefly (shift to Drive and back to Park)
• Re-raise vehicle and inspect drain and fill plugs for any signs of leakage
• Test drive vehicle at low speeds and verify normal operation with no unusual noises from front differential
• After test drive, perform final inspection underneath vehicle for any fluid leaks
• Record mileage and date of service for maintenance tracking

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