Service both front and rear differentials on the 2025 Rivian EDV 500, including draining old gear oil, inspecting components, and refilling with fresh 75W-90 GL-5 gear oil.

Warnings

Tools required

Parts

• Front differential drain plug washer/gasket × 1 — Use OEM specification
• Front differential fill plug washer/gasket × 1 — Use OEM specification
• 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 — 3.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. If recently driven, allow differentials to cool for at least 30 minutes
3. Raise vehicle using appropriate lift or jack and secure on jack stands rated for electric vehicle weight
4. Remove front and rear underbody panels if equipped to access differential drain and fill plugs
5. Clean area around differential drain and fill plugs to prevent contamination
6. Position drain pan under front differential

Procedure

1. 1

   Remove front differential fill plug
   Locate the front differential fill plug on the side of the differential housing. Remove the fill plug first to ensure you can refill the differential after draining. If the fill plug is seized, do not proceed with draining. Use appropriate socket size and break loose carefully to avoid stripping.
2. 2

   Drain front differential
   Position drain pan directly under the front differential drain plug (located at bottom of housing). Remove the drain plug and allow gear oil to fully drain into pan. This will take approximately 5-10 minutes. Inspect drained fluid for excessive metal particles, which may indicate wear issues.
3. 3

   Inspect and clean front differential plugs
   Once fully drained, clean the drain plug threads and magnetic tip (if equipped) with a rag. Inspect the sealing washer/gasket on both drain and fill plugs for damage. Replace washers/gaskets with new OEM parts. Clean the plug holes on the differential housing with a clean rag.
4. 4

   Install front differential drain plug
   Install new drain plug washer/gasket onto drain plug. Thread drain plug into housing by hand to avoid cross-threading. Tighten drain plug to manufacturer specification using torque wrench. Note: Torque specification not available in database - consult Rivian service information or tighten to 25-35 ft-lb as typical for this application.
   ⚠Do not overtighten drain plug as this may damage aluminum housing threads. Use calibrated torque wrench.
5. 5

   Refill front differential
   Using fluid transfer pump or squeeze bottle, add 75W-90 GL-5 gear oil through the fill hole. Fill until oil begins to drip out of the fill hole opening (approximately 1.5 quarts). Allow oil to settle for 30 seconds, then top off if necessary until oil is level with bottom of fill hole threads.
6. 6

   Install front differential fill plug
   Install new fill plug washer/gasket onto fill plug. Thread fill plug into housing by hand, then tighten to manufacturer specification using torque wrench. Note: Torque specification not available in database - consult Rivian service information or tighten to 25-35 ft-lb as typical for this application. Wipe away any spilled oil from differential housing.
7. 7

   Reposition for rear differential service
   Move drain pan to position under rear differential. Clean area around rear differential drain and fill plugs with wire brush and rag to prevent contamination during service.
8. 8

   Remove rear differential fill plug
   Locate the rear differential fill plug on the side of the differential housing. Remove the fill plug first to ensure you can refill the differential after draining. Use appropriate socket size and verify plug breaks free before proceeding to drain.
9. 9

   Drain rear differential
   Position drain pan directly under the rear differential drain plug (located at bottom of housing). Remove the drain plug and allow gear oil to fully drain into pan. This will take approximately 5-10 minutes. Inspect drained fluid for excessive metal particles or unusual odor indicating contamination or overheating.
10. 10

    Inspect and clean rear differential plugs
    Once fully drained, clean the drain plug threads and magnetic tip (if equipped) with a rag. Inspect the sealing washer/gasket on both drain and fill plugs for damage. Replace washers/gaskets with new OEM parts. Clean the plug holes on the differential housing with a clean rag.
11. 11

    Install rear differential drain plug
    Install new drain plug washer/gasket onto drain plug. Thread drain plug into housing by hand to avoid cross-threading. Tighten drain plug to manufacturer specification using torque wrench. Note: Torque specification not available in database - consult Rivian service information or tighten to 25-35 ft-lb as typical for this application.
    ⚠Do not overtighten drain plug as this may damage aluminum housing threads. Use calibrated torque wrench.
12. 12

    Refill rear differential
    Using fluid transfer pump or squeeze bottle, add 75W-90 GL-5 gear oil through the fill hole. Fill until oil begins to drip out of the fill hole opening (approximately 2.0 quarts). Allow oil to settle for 30 seconds, then top off if necessary until oil is level with bottom of fill hole threads.
13. 13

    Install rear differential fill plug
    Install new fill plug washer/gasket onto fill plug. Thread fill plug into housing by hand, then tighten to manufacturer specification using torque wrench. Note: Torque specification not available in database - consult Rivian service information or tighten to 25-35 ft-lb as typical for this application. Wipe away any spilled oil from differential housing.

Reassembly

1. Reinstall any underbody panels or covers that were removed for access
2. Lower vehicle from lift or jack stands
3. Dispose of used gear oil and washers/gaskets according to local environmental regulations
4. Record service in vehicle maintenance log with date and mileage

Verification

• Start vehicle and verify no warning lights or error messages appear on instrument cluster
• Test drive vehicle for 5-10 minutes, including turns and acceleration to circulate fresh gear oil
• After test drive, re-raise vehicle and inspect both differentials for any signs of leakage around drain and fill plugs
• Check fluid level by removing fill plugs - oil should be at bottom of fill hole threads on level ground
• Verify no unusual noise from differentials during operation

More procedures for this vehicle