Complete disassembly, inspection, and rebuild of the front differential assembly on the 2025 Rivian EDV 500, including bearing and seal replacement.

Warnings

Tools required

Parts

• Front differential rebuild kit (includes bearings, seals, shims) × 1 — Use OEM specification
• Differential cover gasket or RTV sealant × 1 — Use OEM specification
• Pinion seal × 1 — Use OEM specification
• Side bearing shims (assorted) × 1 — Use OEM specification
• Pinion bearing shims (assorted) × 1 — Use OEM specification
• Ring gear bolts × 1 — Use OEM specification
• Differential case bearings × 2 — Use OEM specification
• Pinion bearings (inner and outer) × 1 — Use OEM specification
• Crush sleeve or collapsible spacer × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Place vehicle on lift and raise to working height
2. Disconnect 12V battery negative terminal
3. Follow Rivian service procedures to disable high voltage system and install safety lockout plug
4. Remove front wheels
5. Remove front skid plate and underbody panels for access to front drive unit
6. Disconnect front driveshafts from differential flanges and secure out of the way
7. Place drain pan under front differential
8. Support front drive unit with transmission jack before proceeding

Procedure

1. 1

   Drain differential fluid and remove cover
   Remove differential drain plug and drain fluid completely into appropriate container. Remove differential cover bolts in crisscross pattern. Carefully separate cover from housing using pry points. Clean all gasket material from mating surfaces.
2. 2

   Mark and measure gear backlash
   Before disassembly, mount dial indicator to housing with tip on ring gear tooth at 90 degrees to tooth face. Measure and record ring gear backlash by rocking ring gear back and forth while holding pinion stationary. Record measurement for comparison during reassembly. Apply gear marking compound to several ring gear teeth and rotate through mesh to document contact pattern.
3. 3

   Remove differential case assembly
   Remove differential bearing caps (mark left and right for reinstallation). Note position and thickness of any shims behind bearing caps and races. Using pry bars, carefully remove differential case assembly from housing. Keep bearing races and shims organized by side for reference during reassembly.
4. 4

   Remove pinion gear assembly
   Mark pinion flange position relative to pinion shaft. Hold pinion flange and remove pinion nut. Use appropriate puller to remove pinion flange. Tap pinion shaft rearward and remove from housing along with collapsible spacer. Remove pinion seal from housing. Remove pinion bearings and races, keeping inner and outer sets separate.
5. 5

   Disassemble differential case
   Mark ring gear position on differential case. Remove ring gear bolts (may require heat if thread-locking compound used). Press or tap ring gear off case using brass drift. Drive out differential pinion shaft roll pin. Remove pinion shaft, spider gears, and side gears from case. Keep all components organized.
6. 6

   Remove and inspect bearings
   Using bearing puller, remove side bearings from differential case. Inspect all bearings for pitting, scoring, discoloration, or excessive wear. Inspect all gear teeth for chips, cracks, or excessive wear patterns. Inspect differential case and housing for cracks or damage. Replace any worn or damaged components.
7. 7

   Clean and prepare components
   Thoroughly clean all reusable components with appropriate solvent. Clean all bearing bores, gear teeth, and mating surfaces. Inspect housing for cracks, warpage, or damage. Clean and inspect ring gear bolts and replace if threads are damaged or if one-time-use type.
8. 8

   Install new pinion bearings and determine shim thickness
   Press new inner and outer pinion bearing races into housing. Install inner pinion bearing on pinion shaft. Install selected shim stack on pinion shaft (start with original shim thickness if recorded). Install collapsible spacer, outer bearing, and pinion seal. Install pinion flange and nut finger tight. This is a trial assembly to verify pinion depth.
9. 9

   Set pinion depth and preload
   Gradually tighten pinion nut while checking pinion rotating torque with inch-pound torque wrench. Continue tightening until proper pinion bearing preload is achieved (typically 15-30 inch-lbs for new bearings). Do not back off nut to reduce preload - if exceeded, new collapsible spacer must be installed and procedure repeated. Verify pinion depth marking on pinion gear aligns correctly with housing reference.
10. 10

    Reassemble differential case
    Install side gears and spider gears into differential case with appropriate thrust washers. Install pinion shaft through case and gears. Align pinion shaft roll pin hole and install new roll pin. Heat ring gear if necessary and install onto case, aligning match marks. Install new ring gear bolts with thread locking compound and tighten in star pattern.
11. 11

    Install differential case bearings
    Press new side bearings onto differential case hubs. Ensure bearings are fully seated against case shoulders. Install bearing races into housing if not already installed.
12. 12

    Install differential case and set backlash
    Install differential case assembly into housing with original shim packs as starting point. Install bearing caps in correct orientation (reference marks made during disassembly). Hand tighten bearing cap bolts. Mount dial indicator and measure backlash. Adjust shim thickness on both sides to achieve proper backlash (typically 0.005-0.009 inches). Move shims from one side to the other to adjust backlash while maintaining bearing preload. Thicker shim on ring gear side decreases backlash.
13. 13

    Verify gear contact pattern
    Apply gear marking compound to several teeth on ring gear. Rotate pinion through several revolutions in both directions under light resistance. Inspect tooth contact pattern. Pattern should be centered on tooth face. Adjust pinion depth (requires disassembly and shim change) if pattern is too high or low on tooth. Adjust backlash if pattern is too close to toe or heel of tooth.
14. 14

    Final assembly and fill
    Once gear pattern is correct, torque all bearing cap bolts to specification. Apply appropriate RTV sealant or install new gasket on differential cover mating surface. Install differential cover and torque bolts in crisscross pattern. Install and torque drain plug with new sealing washer. Fill differential with 1.5 quarts of 75W-90 GL-5 gear oil through fill hole. Install fill plug with new sealing washer.
15. 15

    Reinstall drive unit components
    Reconnect front driveshafts to differential output flanges. Install underbody panels and front skid plate. Install front wheels. Remove high voltage lockout and reconnect 12V battery. Use Rivian diagnostic scanner to clear any fault codes and perform drive unit initialization procedure if required by service manual.

Reassembly

1. Reassembly is included in the main steps as this is a rebuild procedure requiring precise measurements throughout
2. All fasteners should be torqued to Rivian specifications when available - consult factory service manual
3. Ring gear bolts must be torqued in star pattern to prevent warping
4. Do not reuse collapsible spacer - always install new during pinion setup
5. Verify no metal debris remains in housing before final assembly

Verification

• Check differential fluid level at fill hole after vehicle has been lowered and leveled
• Test drive vehicle and listen for abnormal whining, howling, or clunking from front differential
• Verify no fluid leaks from differential cover, pinion seal, or output shaft seals after test drive
• Recheck fluid level after test drive and top off if necessary
• Perform second test drive including turns in both directions and light acceleration to verify proper gear engagement
• Use Rivian diagnostic scanner to verify no fault codes related to front drive unit
• Monitor differential temperature during initial break-in period - excessive heat indicates improper setup

More procedures for this vehicle