This procedure covers the removal, draining, and replacement of the rear differential fluid on a 2025 Rivian EDV 500 electric delivery van with dual motor AWD configuration.

Warnings

Tools required

Parts

• Rear differential drain plug washer/gasket × 1 — Use OEM specification
• Rear differential fill plug washer/gasket × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks at front wheels
3. If vehicle was recently driven, allow rear differential to cool for at least 30 minutes
4. Raise vehicle using lift or appropriate jack points and secure with jack stands rated for vehicle weight
5. Verify vehicle is stable and secure before proceeding underneath
6. Place vehicle in service/transport mode per manufacturer instructions to ensure drive motors are disabled

Procedure

1. 1

   Access rear differential
   Locate the rear differential housing between the rear wheels. The EDV 500 uses an integrated rear drive unit (RDU) that combines the electric motor and differential assembly. Identify the fill plug (upper) and drain plug (lower) locations on the differential housing.
2. 2

   Clean fill and drain plug areas
   Use a wire brush and shop towels to clean the area around both the fill plug and drain plug. Remove any dirt, debris, or road grime that could contaminate the differential when plugs are removed. This step is critical for preventing contamination of fresh fluid.
3. 3

   Loosen fill plug first
   Before draining, first loosen and remove the fill plug (upper plug) using appropriate socket. This ensures you can refill the differential after draining. If the fill plug is seized or damaged and cannot be removed, do not proceed with draining. Inspect the condition of the fill plug gasket/washer.
4. 4

   Position drain pan and remove drain plug
   Position drain pan directly beneath the drain plug with adequate capacity to catch all fluid. Using appropriate socket, carefully loosen and remove the drain plug. Allow fluid to drain completely, which may take 10-15 minutes. Inspect drained fluid for metal particles, debris, or unusual odor which may indicate internal wear.
5. 5

   Inspect and clean drain plug
   Once fluid has fully drained, inspect the drain plug for metal particles on the magnetic tip (if equipped). Clean the drain plug thoroughly with shop towels and solvent if necessary. Inspect the drain plug threads for damage. Remove and discard the old drain plug washer/gasket.
6. 6

   Clean drain plug opening
   Wipe the drain plug opening and surrounding area clean with shop towels. Use a plastic scraper if necessary to remove any gasket material or buildup. Ensure no debris or contaminants will enter when the drain plug is reinstalled.
7. 7

   Install drain plug with new washer
   Install a new drain plug washer/gasket onto the drain plug. Thread the drain plug into the differential housing by hand to ensure proper thread engagement. Tighten the drain plug to manufacturer specification using a torque wrench. Note: Specific torque values not available in database - consult Rivian service documentation for exact specification.
8. 8

   Fill differential with new fluid
   Using a fluid transfer pump or squeeze bottle with appropriate nozzle, begin filling the differential through the fill plug opening. Add 75W-90 GL-5 gear oil slowly to prevent overflow. The rear differential capacity is 2.0 quarts. Fill until fluid begins to drip from the fill plug opening, indicating proper level.
9. 9

   Install fill plug
   Install a new fill plug washer/gasket onto the fill plug. Allow excess fluid to drain back for approximately 30 seconds, then thread the fill plug into the housing by hand. Tighten the fill plug to manufacturer specification using a torque wrench. Note: Specific torque values not available in database - consult Rivian service documentation.
10. 10

    Clean exterior and inspect for leaks
    Wipe down the differential housing exterior to remove any spilled fluid. Inspect both the drain plug and fill plug for signs of leakage. Clean the surrounding area to ensure any future leaks can be easily identified.
11. 11

    Lower vehicle and verify operation
    Remove jack stands and carefully lower the vehicle to the ground. Remove wheel chocks. Exit service mode per manufacturer instructions. Start the vehicle and allow the drive system to initialize. Test drive the vehicle at low speed, making several turns in both directions to distribute fluid throughout the differential.

Reassembly

1. Ensure both drain and fill plugs are torqued to specification with new washers/gaskets installed
2. Verify no fluid leaks are present at either plug location
3. Dispose of used differential fluid according to local environmental regulations
4. Record the service in vehicle maintenance logs with date and mileage

Verification

• Check for fluid leaks around drain and fill plugs after initial test drive
• Re-inspect plug areas after 50-100 miles of driving to confirm no seepage
• Listen for any unusual noises from rear differential during operation, which could indicate improper fill level or air in system
• Verify smooth operation during turns and acceleration with no grinding or whining noises

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