ev-battery

High Voltage Battery Pack R&R

for 2025 Rivian EDV 500 Dual Motor AWD (EDV) · AWD

Editorial review:Chris Hackleman — Master Technician · 20+ years · Jeff Moore — Master Lexus & Toyota Mechanic · 20+ years

Difficulty

Expert

Time

7.5 h

Tools

Steps

✓Expert-verified. Personally reviewed and approved by OLP's master technicians (Chris Hackleman & Jeff Moore — 20+ years each). Always follow the vehicle's factory service information and torque specs.

Complete removal and replacement of the high voltage battery pack assembly on a 2025 Rivian EDV 500, including disconnection of all high voltage systems, coolant drainage, and structural fastener removal.

Warnings

⚠️HIGH VOLTAGE SYSTEM: This vehicle contains up to 800V DC that can cause INSTANT DEATH. Only qualified technicians with high voltage training should perform this procedure.

⚠️Wait minimum 15 minutes after disconnecting high voltage system before touching any orange cables. Capacitors remain charged and lethal during this period.

⚠️Battery pack weighs approximately 1,800 lbs. Use proper lifting equipment and ensure adequate support at all times. Crush hazard.

⚠️Damaged battery cells can cause thermal runaway, fire, and toxic gas release. Inspect battery for any signs of damage before removal. If damage is present, follow Rivian emergency procedures.

⚠EV coolant is toxic and harmful to environment. Collect and dispose of properly according to local regulations.

⚠Never work alone on high voltage systems. A second person must be present who is trained in high voltage rescue procedures.

ℹ️Vehicle must be on level ground. Battery removal on an incline creates significant safety risk.

ℹ️If you are not absolutely certain about any step in this procedure, STOP and contact a Rivian-certified service center.

Tools required

High voltage safety gloves (Class 0, 1000V rated)Essential

High voltage multimeter (CAT III 1000V rated)Essential

Battery lift table or transmission jack (1000 lb capacity minimum)Essential

Rivian diagnostic tool or compatible OBD2 scan tool with EV capabilityEssential

Torque wrench set (10-200 ft-lb range)Essential

Socket set (metric, 8mm-21mm)Essential

Coolant drain pan (15 quart capacity minimum)Essential

High voltage disconnect lockout tagsEssential

Vehicle lift (4-post recommended)Essential

T30 and T45 Torx drivers

Plastic trim removal tools

Wire brush for terminal cleaning

Dielectric grease

Parts

High voltage battery pack assembly × 1 — Use OEM specification
Battery coolant quick-disconnect O-rings × 2 — Use OEM specification
HV battery mounting hardware kit × 1 — Use OEM specification
HV interlock connector seal × 1 — Use OEM specification
Battery pack perimeter seal × 1 — Use OEM specification

Fluids

EV Battery/Motor Coolant — 10 qt

Preparation

Verify vehicle is parked on level ground in a well-ventilated area away from ignition sources
Ensure second trained person is present for entire procedure
Connect Rivian diagnostic tool and document all stored fault codes
Verify battery state of charge is below 30% (discharge if necessary using Rivian service mode)
Place wheel chocks at all four wheels
Disconnect 12V auxiliary battery negative terminal and wait 5 minutes
Put on high voltage safety gloves and face shield
Lift vehicle on 4-post lift to comfortable working height (minimum 36 inches underbody clearance)
Remove all four wheels and set aside
Remove complete underbody splash shield and aerodynamic panels
Place coolant drain pans under battery coolant quick-disconnects
Have fire extinguisher rated for lithium battery fires (Class D) immediately available

Procedure

1
Access and isolate high voltage system
Remove rear cargo area floor panel to access battery service disconnect. Wearing HV safety gloves, unlock and pull the orange high voltage service disconnect handle. Install lockout tag on disconnect. Use HV multimeter to verify zero voltage at service disconnect terminals (must read less than 5V DC). Wait mandatory 15 minutes for HV capacitor discharge.
2
Verify high voltage isolation
Using CAT III rated multimeter, verify voltage between HV positive bus and chassis ground reads less than 5V DC. Verify voltage between HV negative bus and chassis ground reads less than 5V DC. Document readings. If any reading exceeds 5V, do not proceed - contact Rivian technical support.
3
Disconnect high voltage interlock loop
Locate orange HV interlock connector near battery service disconnect. Press release tab and disconnect interlock connector. Secure connector away from battery area. This breaks the safety interlock circuit preventing HV contactors from closing.
4
Drain battery thermal management coolant
Working from underneath vehicle, locate two battery coolant quick-disconnect fittings on driver side of battery pack. Slide outer collar back on each fitting and pull to disconnect. Allow approximately 10 quarts of EV coolant to drain into collection pan. Cap open coolant lines to prevent contamination.
5
Disconnect main high voltage cables
Locate main HV positive and negative cables at front of battery pack (orange cables with yellow safety covers). Remove yellow safety covers. Remove cable mounting bolts using appropriate socket. Carefully lift cables away from battery terminals and secure to vehicle frame. Inspect terminals for any signs of arcing or damage.
6
Disconnect battery management system harness
Locate Battery Management System (BMS) connector at rear of battery pack (gray multi-pin connector). Depress connector lock tab and disconnect. Release harness from routing clips along battery edge. Secure harness to vehicle frame away from battery removal path.
7
Disconnect battery heating elements
Locate battery heater electrical connectors on passenger side of pack (two large black connectors). Depress connector locks and disconnect both heater circuits. Release from routing clips and secure to vehicle frame.
8
Remove front battery mounting bolts
Locate six front battery mounting bolts through access holes in front subframe. Remove bolts using appropriate socket. Note location of any different length bolts or washers. Battery pack is now supported only by rear mounts and side supports - ensure lift table is positioned but not yet engaged.
9
Position battery lift table
Carefully position battery lift table or transmission jack under center of battery pack. Use padded lifting blocks to distribute load across battery structure. Raise lift table until it just contacts battery pack bottom - DO NOT lift yet. Verify lift is centered and stable.
10
Remove side support brackets
Remove battery side support brackets on both driver and passenger sides (four bolts per side). These brackets provide lateral stability. With brackets removed, battery is now only held by rear mounting bolts. Verify lift table is properly supporting battery weight.
11
Remove rear battery mounting bolts
Locate six rear battery mounting bolts through access holes in rear subframe. While ensuring lift table is supporting full battery weight, remove all rear mounting bolts. Battery pack is now completely free from vehicle and supported only by lift table.
12
Lower and remove battery pack
Very slowly lower lift table, constantly monitoring for any obstructions or hanging wires. Lower battery pack approximately 12 inches below chassis. Carefully roll lift table rearward to extract battery pack from vehicle. Move battery pack to safe, level storage location away from traffic. Never stack anything on top of battery pack.
13
Inspect battery mounting points and vehicle chassis
With battery removed, inspect all mounting points for damage, corrosion, or cracks. Inspect chassis rails for any signs of impact or deformation. Check coolant lines for leaks or damage. Clean all mounting surfaces with wire brush. If any structural damage is found, vehicle chassis must be repaired before installing new battery.
14
Prepare replacement battery pack
Inspect new/replacement battery pack for any shipping damage. Verify pack is correct specification for vehicle (check label on battery pack). Install new perimeter seal around battery edge if not pre-installed. Apply thin coat of dielectric grease to HV terminal connection points. Position battery pack on lift table in same orientation as removed pack.
15
Install replacement battery pack
Carefully roll lift table with battery pack underneath vehicle, aligning with mounting points. Slowly raise battery pack, ensuring no wires or hoses are pinched. Align mounting holes with chassis mounts. Install rear mounting bolts finger-tight first, then front mounting bolts finger-tight. Torque all mounting bolts to specification per Rivian service manual (specification not available in database - reference OEM service data). Install side support brackets.

Reassembly

Reconnect battery heating element connectors and secure harness in routing clips
Reconnect Battery Management System harness connector and verify lock engages
Reconnect main HV positive and negative cables to battery terminals - torque per Rivian specification
Install yellow safety covers over HV terminals
Reconnect battery coolant quick-disconnect fittings - push fully until click is heard and verify lock engagement
Reconnect HV interlock loop connector
Refill battery thermal management system with 10 quarts EV Battery/Motor Coolant using Rivian service tool fill procedure
Reinstall underbody splash shields and aerodynamic panels
Reinstall all four wheels and torque lug nuts to specification
Lower vehicle to ground
Remove lockout tag from HV service disconnect and reinstall disconnect handle
Reconnect 12V auxiliary battery negative terminal

Verification

Using Rivian diagnostic tool, clear all stored fault codes and perform battery system initialization procedure
Verify no HV isolation faults are present - resistance between HV system and chassis ground must exceed 100 ohms per volt (minimum 80k ohms for 800V system)
Check for coolant leaks at quick-disconnect fittings - start vehicle in service mode and observe for drips
Verify Battery Management System communication - all cell voltage readings should be present and balanced
Perform initial charge cycle - charge battery to 80% and verify proper charging current and no thermal alerts
Test drive vehicle and verify normal operation of both drive motors and no loss of power
Verify no warning lights or HV system faults are displayed on instrument cluster
Perform final diagnostic scan and document all system parameters are within normal range
Inspect underbody for any loose fasteners or components after test drive