Complete removal and replacement of the rear differential assembly on a 2025 Rivian EDV 500 dual motor AWD electric delivery van, including draining and refilling gear oil.

Warnings

Tools required

Parts

• Rear differential assembly × 1 — Use OEM specification
• Differential mounting bolts × 1 — Use OEM specification
• Axle flange seals × 2 — Use OEM specification
• Differential fill/drain plug gaskets × 2 — Use OEM specification
• Differential breather assembly × 1 — Use OEM specification if damaged

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal and wait minimum 5 minutes for capacitor discharge
3. Raise vehicle on lift or secure on jack stands at manufacturer-specified lift points
4. Remove rear wheels and set aside
5. Place wheel chocks at front wheels
6. Verify high voltage system is de-energized using Rivian diagnostic software
7. Position hydraulic transmission jack under rear differential assembly
8. Clean area around differential housing to prevent contamination during disassembly

Procedure

1. 1

   Drain rear differential fluid
   Position drain pan under rear differential. Locate and remove the differential drain plug at the bottom of the housing. Allow fluid to drain completely for at least 10 minutes. Remove fill plug to expedite draining. Inspect drained fluid for metal particles or unusual debris that may indicate internal damage.
2. 2

   Disconnect rear drive axles
   Remove the axle flange bolts on both driver and passenger sides connecting the CV axles to the differential output flanges. Mark the orientation of flanges for reinstallation. Support the axle shafts with wire or mechanics wire to prevent damage to CV boots. Do not allow axles to hang freely.
3. 3

   Disconnect electrical connectors
   Locate and disconnect all electrical connectors attached to the rear motor/differential assembly. This includes the motor phase connectors, speed sensors, and temperature sensors. Use a digital multimeter to verify no voltage present before disconnecting. Label each connector with tape for proper reassembly.
4. 4

   Remove differential breather hose
   Disconnect the differential breather hose from the top of the differential housing. Note the routing for reinstallation. Cap or plug the hose to prevent contamination.
5. 5

   Support differential with transmission jack
   Position hydraulic transmission jack directly under the center of the rear differential assembly. Raise jack until it just contacts the housing. Secure the differential to the jack using a chain or strap to prevent shifting during removal. The assembly weighs approximately 180 lbs.
6. 6

   Remove rear differential mounting bolts
   Locate all differential mounting bolts securing the assembly to the rear subframe. Typically there are 4-6 main mounting points. Remove bolts in a cross-pattern, leaving two opposite bolts partially threaded until last. Support the differential weight with the transmission jack throughout this process.
7. 7

   Lower and remove differential assembly
   With all mounting bolts removed, carefully lower the transmission jack while guiding the differential assembly clear of the vehicle. Watch for any remaining electrical connections or mechanical interference. Angle the assembly as needed to clear the subframe and suspension components. Remove assembly from under vehicle.
8. 8

   Inspect mounting points and seals
   With differential removed, inspect all mounting points on the subframe for damage, cracks, or elongation. Check axle flange seals in the differential housing and replace if installing a used differential. Inspect CV axle boots for tears or damage. Clean all mounting surfaces thoroughly.
9. 9

   Prepare new differential for installation
   If installing a new or remanufactured differential, verify it matches the original part number and gear ratio. Check that fill and drain plugs are properly torqued. Install new axle flange seals using a seal driver if not already installed. Verify breather is installed and clear.
10. 10

    Position and raise differential into place
    Secure the replacement differential to the transmission jack using chain or strap. Carefully raise the assembly into position under the vehicle, aligning it with the mounting points on the rear subframe. Angle as necessary to clear suspension components. Guide the assembly until mounting holes align.
11. 11

    Install differential mounting bolts
    Start all differential mounting bolts by hand to ensure proper thread engagement. Apply medium-strength thread locker to bolt threads per manufacturer specification. Tighten bolts in a cross-pattern to ensure even seating. Since specific torque values are not available in the database, tighten to manufacturer specification found in service manual.
12. 12

    Reconnect electrical connections
    Reconnect all electrical connectors to the rear motor/differential assembly in the reverse order of removal, using labels as reference. Ensure each connector locks securely with an audible click. Verify proper seating of high-voltage connections and phase connectors. Check that no wires are pinched or under tension.
13. 13

    Reconnect drive axles
    Align the CV axle flanges with the differential output flanges using the orientation marks made during disassembly. Install new axle flange bolts and tighten in a star pattern. Ensure axles are fully seated and have no excessive play. Verify CV boots are not damaged or twisted.
14. 14

    Refill differential with gear oil
    Using a gear oil pump, refill the rear differential through the fill hole with 2.0 quarts of 75W-90 GL-5 gear oil. Fill until oil begins to seep from the fill hole, indicating proper level. Install new fill plug gasket and reinstall fill plug. Install new drain plug gasket if not already done.
15. 15

    Reconnect breather hose and perform system checks
    Reconnect the differential breather hose following the original routing. Ensure it is not kinked or restricted. Reconnect 12V battery. Use Rivian diagnostic software to clear any fault codes and perform rear drive unit calibration procedure. Verify no warning lights are present on instrument cluster.

Reassembly

1. Reinstall rear wheels and torque lug nuts to manufacturer specification
2. Lower vehicle to ground
3. Perform final torque verification on all mounting bolts and axle flange bolts
4. Recheck differential fluid level after vehicle has settled
5. Road test vehicle at low speed in a safe area to verify proper operation
6. Monitor for unusual noises, vibrations, or warning lights

Verification

• Start vehicle and verify no warning lights or fault codes are present using diagnostic scanner
• Test vehicle in forward and reverse at low speed to confirm differential engagement
• Verify no fluid leaks from differential housing, drain plug, or fill plug
• Check that all electrical connections are secure and show no fault codes
• Perform regenerative braking test to confirm rear motor operation
• Verify proper AWD operation by observing power distribution during acceleration
• Recheck differential fluid level after initial test drive and top off if necessary
• Confirm no abnormal noises from rear differential during operation

More procedures for this vehicle