Differential Rebuild - Rear

Complete disassembly, inspection, and rebuild of the rear differential assembly on a 2025 Rivian EDV 500 dual motor AWD electric delivery van, including bearing and seal replacement.

Warnings

Tools required

Parts

• Rear differential gasket kit × 1 — Use OEM specification
• Rear differential bearing kit (includes all bearings) × 1 — Use OEM specification
• Rear differential seal kit × 1 — Use OEM specification
• Pinion nut (single use) × 1 — Use OEM specification
• Ring gear bolts (if damaged) × 10 — Use OEM specification
• Crush sleeve or preload shims × 1 — Use OEM specification
• RTV silicone sealant (OEM approved for differentials) × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 2.5 qt

Preparation

1. Verify vehicle is on level surface and properly supported on lift or heavy-duty jack stands
2. Disconnect 12V battery negative terminal and wait 10 minutes
3. Verify high voltage system is safely disabled per Rivian service procedures
4. Remove rear wheels and set aside
5. Place drain pan under rear differential
6. Allow differential to cool to ambient temperature if vehicle was recently driven
7. Clean exterior of differential housing thoroughly to prevent contamination
8. Take reference photos of axle assembly orientation for reassembly
9. Label all components during disassembly with their position and orientation

Procedure

1. 1

   Drain differential fluid and remove axle shafts
   Remove differential drain plug and allow fluid to drain completely into pan. Inspect drained fluid for metal particles indicating wear. Remove axle shaft retaining bolts and carefully pull axle shafts from differential housing. Support axle shafts to prevent damage to CV joints.
2. 2

   Remove differential housing from vehicle
   Disconnect driveshaft from differential input flange. Remove differential mounting bolts securing housing to subframe or suspension mounts. Support differential weight with transmission jack. Carefully lower differential assembly from vehicle and place on clean workbench.
3. 3

   Remove differential cover and inspect internal components
   Remove differential cover bolts in crisscross pattern. Carefully pry cover off housing using plastic pry tools. Inspect gear teeth for wear, pitting, or damage. Check for metal debris in housing. Photograph gear contact pattern using gear marking compound if gears are being reused (not recommended). Rotate ring gear and check for smooth operation.
4. 4

   Measure and record bearing preload and backlash
   Using inch-pound torque wrench on pinion nut, measure and record rotating torque (should be 15-25 in-lbs typically). Mount dial indicator on housing with plunger against ring gear tooth. Rock ring gear back and forth and measure backlash at 4 points around gear (should be 0.005-0.008 inches typically). Record all measurements for reference.
5. 5

   Remove differential carrier assembly
   Remove carrier bearing cap bolts. Mark bearing caps and housing for correct reinstallation orientation. Carefully pry carrier assembly out of housing using pry points. Remove and label all shims from both sides of carrier bearings. Place carrier assembly on workbench.
6. 6

   Remove pinion gear assembly
   Hold pinion flange with holding tool and remove pinion nut (this is a single-use nut and must be replaced). Using appropriate puller, remove pinion flange. Tap pinion gear out of housing from front using soft hammer. Remove pinion seal, front pinion bearing, crush sleeve or shims, and rear pinion bearing. Keep all components organized and labeled.
7. 7

   Remove and inspect ring gear
   Mark ring gear orientation to carrier before removal. Remove ring gear mounting bolts (may require heat if using thread locker). Separate ring gear from carrier using soft hammer taps. Inspect ring gear and pinion teeth for wear patterns, scoring, or damage. Check gear runout by mounting ring gear on carrier and measuring with dial indicator (should be less than 0.003 inches).
8. 8

   Remove carrier bearings and races
   Using appropriate bearing puller, remove carrier bearings from differential carrier. Drive out bearing races from housing using race driver and hammer. Remove pinion bearing races from housing using slide hammer with internal puller attachment. Clean all bearing surfaces thoroughly and inspect for wear, pitting, or damage.
9. 9

   Clean and inspect all components
   Thoroughly clean housing, carrier, and all reusable components with solvent. Inspect housing for cracks, especially around bearing bores and mounting points. Check carrier for cracks or damage. Inspect gear teeth under magnification for micro-cracks or spalling. Replace any components showing wear or damage. Clean all bolt holes and threaded surfaces.
10. 10

    Install new bearing races and assemble carrier
    Using bearing race driver set and press, install new carrier bearing races squarely into housing. Install new pinion bearing races into housing, ensuring they are fully seated. Install new carrier bearings onto differential carrier using press and appropriate adapters. Do not damage bearing seals during installation.
11. 11

    Install ring gear to carrier
    Clean and inspect ring gear mounting surface on carrier. Align ring gear to carrier using previously marked orientation. Install new ring gear bolts with thread locking compound applied. Tighten bolts in star pattern to proper specification in three stages: first to 1/3 torque, then 2/3 torque, then final torque. Verify ring gear runout is within specification using dial indicator.
12. 12

    Install pinion gear with bearing preload setup
    Install rear pinion bearing onto pinion shaft using press and appropriate driver. Install pinion assembly into housing from rear. Install new crush sleeve or appropriate shim pack (based on previous measurements and new bearing specifications). Install front pinion bearing. Install new pinion seal using seal driver, ensuring proper depth. Install pinion flange and new pinion nut.
13. 13

    Set pinion bearing preload
    Hold pinion flange and tighten pinion nut gradually while checking bearing preload. Target preload is typically 15-25 in-lbs rotating torque for new bearings (10-15 in-lbs for used bearings). Tighten nut in small increments, checking preload frequently with inch-pound torque wrench. Do not back off nut if overtightened; must start over with new crush sleeve. Once correct preload is achieved, verify pinion rotates smoothly without binding.
14. 14

    Install carrier assembly and set backlash
    Install original shim pack on carrier bearings as starting point. Carefully install carrier assembly into housing, ensuring bearings seat properly in races. Install bearing caps in correct orientation matching marks made during disassembly. Finger tighten cap bolts. Using dial indicator, measure backlash at multiple points around ring gear. Adjust shim thickness to achieve proper backlash (typically 0.005-0.008 inches). Move shims from one side to other to adjust backlash without changing bearing preload. Thicker shim on ring gear side decreases backlash; thicker shim on opposite side increases backlash.
15. 15

    Check gear contact pattern and finalize assembly
    Apply thin coat of gear marking compound to ring gear teeth. Rotate pinion and ring gear through several revolutions under light load. Inspect contact pattern on gear teeth; pattern should be centered on tooth face. Adjust pinion depth shims if pattern is too high or low on tooth (requires pinion disassembly). Once pattern is correct, tighten carrier bearing cap bolts to specification in crisscross pattern. Recheck backlash and bearing preload after tightening. Clean marking compound from gears. Apply thin bead of RTV sealant to differential cover mating surface. Install cover and tighten bolts in crisscross pattern. Allow RTV to cure per manufacturer instructions before filling with fluid.

Reassembly

1. Reinstall differential assembly into vehicle, ensuring all mounting points align properly
2. Torque all differential mounting bolts to specification
3. Reconnect driveshaft to differential input flange with new bolts if specified
4. Install new axle shaft seals and reinstall axle shafts with new retaining bolts
5. Fill differential with 2.0-2.5 quarts of 75W-90 GL-5 gear oil through fill port until oil reaches bottom of fill hole
6. Install fill plug with new crush washer if equipped
7. Reinstall rear wheels and torque lug nuts to specification in star pattern
8. Reconnect 12V battery negative terminal

Verification

• Start vehicle and verify no warning lights related to drivetrain are illuminated
• Test drive vehicle at various speeds, listening for abnormal noises from rear differential
• Check for gear whine under acceleration and deceleration
• Verify smooth operation during turns (no binding or chattering)
• After 50-100 miles, recheck differential fluid level and inspect for leaks around cover and seals
• After 500 miles, drain and refill differential fluid to remove any break-in debris
• Monitor differential temperature during normal operation to ensure proper heat dissipation

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