This procedure covers the removal and replacement of the front differential assembly on a 2025 Rivian EDV 500 Dual Motor AWD electric delivery van.

Warnings

Tools required

Parts

• Front differential assembly (if replacing complete unit) × 1 — Use OEM specification
• Front differential cover gasket × 1 — Use OEM specification
• Drain plug washer × 1 — Use OEM specification
• Fill plug washer × 1 — Use OEM specification
• Front differential mounting bolts × 1 — Replace if damaged or corroded
• CV axle seals × 2 — Use OEM specification
• Electrical connector seals × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disable high voltage system following Rivian service procedures and install lockout/tagout device
3. Disconnect 12V auxiliary battery negative terminal
4. Raise vehicle on lift or jack stands to provide adequate working clearance underneath
5. Remove front wheels and set aside
6. Place drain pan under front differential
7. Document or photograph electrical connector positions and routing for reassembly
8. Allow differential to cool if vehicle was recently driven (minimum 30 minutes)

Procedure

1. 1

   Drain front differential fluid
   Locate the drain plug on the bottom of the front differential housing. Clean the area around the drain plug. Using the appropriate socket, remove the drain plug and allow all gear oil to drain completely into the drain pan. Inspect the drained fluid for metal particles or contamination that may indicate internal damage. Remove the fill plug on the side of the differential to ensure complete drainage and ventilation.
2. 2

   Disconnect front drive axles
   Remove the bolts securing both front CV axles to the differential output flanges. Support the axles with wire or zip ties to prevent them from hanging and damaging the CV boots. Mark left and right sides to ensure proper reassembly. Inspect CV axle boots for damage while accessible.
3. 3

   Disconnect electrical connections
   Locate and carefully disconnect all electrical connectors from the front motor/differential assembly. This typically includes motor power connections, position sensors, and temperature sensors. Use the multimeter to verify no voltage is present before disconnecting. Secure connectors away from work area to prevent damage.
4. 4

   Remove protective shields and covers
   Remove any underbody protective shields, heat shields, or covers that obstruct access to the differential mounting points. These are typically secured with a combination of bolts and push clips. Keep all fasteners organized for reinstallation.
5. 5

   Disconnect cooling lines
   If equipped with dedicated differential/motor cooling lines, carefully disconnect them from the differential housing. Have a drain pan ready as some coolant may spill. Cap or plug open lines to prevent contamination. Note the routing and orientation of coolant lines for proper reconnection.
6. 6

   Support differential with jack
   Position the transmission jack or differential jack under the center of the front differential assembly. Raise the jack just enough to make contact and support the weight, but do not lift the differential. Ensure the differential is stable on the jack before proceeding.
7. 7

   Remove front differential mounting bolts
   Locate all differential mounting bolts connecting the assembly to the front subframe or crossmember. There are typically 4-6 main mounting bolts. Using a breaker bar if necessary, remove all mounting bolts while maintaining support with the jack. Keep bolts organized and inspect threads for damage.
8. 8

   Remove motor/differential assembly
   With all mounting bolts removed and connections disconnected, carefully lower the differential assembly on the jack. Guide the assembly down and away from the vehicle, being careful not to damage any surrounding components, brake lines, or wiring. Maneuver the assembly out from under the vehicle. This may require adjusting jack height and angle.
9. 9

   Inspect mounting points and prepare for installation
   With the differential removed, inspect all mounting points on the subframe for damage, cracks, or corrosion. Clean mounting surfaces with a wire brush. Inspect the differential mounting brackets and bushings on the replacement or serviced unit. Replace any damaged bushings or mounts. If installing a used or rebuilt differential, verify all seals are in good condition.
10. 10

    Install differential assembly
    Place the front differential assembly on the transmission jack and carefully raise it into position under the vehicle. Align the mounting points with the subframe brackets. This may require small adjustments to jack position and height. Once aligned, thread in all mounting bolts by hand to ensure proper threading. Tighten mounting bolts in a star pattern to ensure even seating. Without torque specifications available, tighten securely to manufacturer standards, typically 80-100 ft-lbs for main structural mounting bolts on electric drive units.
11. 11

    Reconnect cooling lines and verify seal
    If equipped with cooling lines, reconnect them to the differential assembly ensuring proper orientation and routing matches original configuration. Tighten fittings to specification and verify connections are secure with no cross-threading.
12. 12

    Reconnect drive axles
    Guide both front CV axles back into position and align with the differential output flanges. Install mounting bolts and tighten in a cross pattern. Without specific torque values, tighten CV axle flange bolts to a typical specification of 50-60 ft-lbs for this vehicle class, ensuring all bolts are uniformly tight.
13. 13

    Reconnect all electrical connections
    Reconnect all electrical connectors to the motor and differential assembly in the reverse order of removal, referencing your documentation or photos. Ensure all connectors are fully seated and locking tabs are engaged. Verify connector seals are in place to maintain weatherproofing.
14. 14

    Fill differential with gear oil
    Install a new washer on the drain plug and reinstall the drain plug, tightening securely. Using a fluid pump, fill the front differential through the fill hole with 1.5 quarts of 75W-90 GL-5 gear oil. Fill until oil begins to seep from the fill hole, indicating proper level. Install a new washer on the fill plug and reinstall, tightening securely.
15. 15

    Reinstall protective covers and wheels
    Reinstall all underbody shields, protective covers, and heat shields removed during disassembly. Ensure all fasteners are properly secured. Reinstall front wheels and torque lug nuts to specification (typically 120-140 ft-lbs for this vehicle class).

Reassembly

1. Double-check all electrical connections are secure and properly seated
2. Verify all cooling line connections are tight and not leaking
3. Confirm all mounting bolts are properly torqued
4. Ensure no tools or parts are left in the work area
5. Remove lockout/tagout devices from high voltage system
6. Reconnect 12V auxiliary battery

Verification

• Lower vehicle to ground and perform visual inspection underneath for any leaks or loose components
• Enable high voltage system following Rivian procedures
• Start vehicle and verify no warning lights or error codes related to front drive unit
• Test drive vehicle in a safe area, verifying proper operation of front motor and AWD system
• Listen for abnormal noises from front differential during acceleration and turning
• After test drive, raise vehicle and inspect for any fluid leaks from differential, particularly around drain/fill plugs and axle seals
• Verify differential oil level is correct after initial drive cycle
• Use Rivian diagnostic software if available to verify motor temperature sensors and drive unit functionality
• Re-torque all fasteners after 50-100 miles of operation

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