This procedure covers the removal and replacement of differential fluid for both front and rear differentials on the 2025 Rivian EDV 500 Dual Motor AWD electric delivery van.

Warnings

Tools required

Parts

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

Fluids

• 75W-90 GL-5 Gear Oil — 3.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been off for at least 30 minutes to allow differential fluid to cool
3. Place wheel chocks behind rear wheels if using a lift, or all wheels not being raised if using jack stands
4. Raise vehicle to working height and secure on lift locks or jack stands at manufacturer-specified lift points
5. Verify vehicle stability before working underneath
6. Have new gaskets and required quantity of gear oil readily accessible

Procedure

1. 1

   Access front differential
   Locate the front differential assembly between the front wheels. Identify the fill plug on the upper portion of the differential housing and the drain plug on the lower portion. Clean the area around both plugs with a wire brush to remove dirt and debris that could contaminate the differential.
2. 2

   Remove front differential fill plug
   Using the appropriate socket, carefully loosen and remove the front differential fill plug. Inspect the condition of the plug and sealing surface. If a magnetic drain plug, clean any metallic debris and inspect for excessive material which could indicate internal wear. Set aside with the old gasket for disposal.
3. 3

   Drain front differential
   Position drain pan beneath the front differential drain plug. Remove the drain plug completely and allow fluid to drain fully into the pan. This should take 5-10 minutes for complete drainage. Inspect the drained fluid for metal particles, discoloration, or contamination. Excessive metal content may indicate internal damage requiring further inspection.
4. 4

   Reinstall front differential drain plug
   Clean the drain plug threads and magnetic tip if equipped. Install a new gasket onto the drain plug. Thread the drain plug into the differential housing by hand to avoid cross-threading, then tighten to specification per manufacturer torque requirements. Note: Torque specification not provided in database - consult Rivian service manual for exact value.
5. 5

   Refill front differential
   Using a fluid transfer pump, add 1.5 quarts of 75W-90 GL-5 gear oil through the fill plug opening. Fill until fluid begins to seep from the fill hole, indicating proper level. Allow fluid to stabilize for 1-2 minutes and top off if necessary.
6. 6

   Install front differential fill plug
   Clean the fill plug threads and install a new gasket. Thread the fill plug in by hand, then tighten to specification per manufacturer torque requirements. Wipe away any excess fluid from the differential housing.
7. 7

   Access rear differential
   Locate the rear differential assembly between the rear wheels. Identify the fill plug on the upper portion of the differential housing and the drain plug on the lower portion. Clean the area around both plugs with a wire brush to remove dirt and debris.
8. 8

   Remove rear differential fill plug
   Using the appropriate socket, carefully loosen and remove the rear differential fill plug. Inspect the condition of the plug and sealing surface. If a magnetic drain plug, clean any metallic debris and inspect for excessive material. Set aside with the old gasket for disposal.
9. 9

   Drain rear differential
   Position drain pan beneath the rear differential drain plug. Remove the drain plug completely and allow fluid to drain fully into the pan. This should take 5-10 minutes for complete drainage. Inspect the drained fluid for metal particles, discoloration, or contamination. The rear differential holds 2.0 quarts, so expect slightly more fluid than the front.
10. 10

    Reinstall rear differential drain plug
    Clean the drain plug threads and magnetic tip if equipped. Install a new gasket onto the drain plug. Thread the drain plug into the differential housing by hand to avoid cross-threading, then tighten to specification per manufacturer torque requirements. Note: Torque specification not provided in database - consult Rivian service manual for exact value.
11. 11

    Refill rear differential
    Using a fluid transfer pump, add 2.0 quarts of 75W-90 GL-5 gear oil through the fill plug opening. Fill until fluid begins to seep from the fill hole, indicating proper level. Allow fluid to stabilize for 1-2 minutes and top off if necessary.
12. 12

    Install rear differential fill plug
    Clean the fill plug threads and install a new gasket. Thread the fill plug in by hand, then tighten to specification per manufacturer torque requirements. Wipe away any excess fluid from the differential housing.

Reassembly

1. Perform a final inspection of both differentials to ensure drain and fill plugs are properly tightened
2. Check for any fluid leaks around plug areas
3. Clean any spilled gear oil from the undercarriage and differential housings
4. Lower vehicle from lift or jack stands
5. Remove wheel chocks

Verification

• Start the vehicle and allow it to idle for 2-3 minutes to circulate differential fluid
• Perform a short test drive (1-2 miles) at varying speeds, including turns in both directions to distribute fluid throughout the differential gears
• After test drive, raise vehicle again and inspect both differentials for any signs of leakage around drain and fill plugs
• Check fluid levels again by briefly removing fill plugs - fluid should be at the bottom of the fill hole threads
• Record the service in the vehicle maintenance log with date and mileage

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