This procedure covers the removal and replacement of the rear window regulator assembly on a 2025 Rivian EDV 500 commercial delivery van.

Warnings

Tools required

Parts

• Rear window regulator assembly × 1 — Use OEM specification
• Door panel trim clips × 1 — Replacement clip assortment
• Vapor barrier adhesive tape × 1 — OEM or equivalent

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V auxiliary battery negative terminal located in front compartment
3. Wait minimum 2 minutes for system capacitors to discharge
4. Roll rear window to approximately mid-travel position if operational before disconnecting battery
5. Gather all tools and replacement parts
6. Photograph door panel fastener locations for reference during reassembly

Procedure

1. 1

   Remove door panel lower trim fasteners
   Using the T25 Torx driver, remove all visible Torx screws from the lower perimeter of the rear door panel. Typically there are 2-3 screws along the bottom edge and 1-2 in the door pull/handle area. Store screws in a container to prevent loss.
2. 2

   Disconnect door handle switch assembly
   Locate the door handle switch bezel or control panel on the armrest. Use a panel removal tool to gently pry the switch assembly upward. Disconnect the electrical connector by pressing the release tab and pulling straight away from the switch. Set switch assembly aside in a safe location.
3. 3

   Release door panel retaining clips
   Starting at the bottom rear corner, insert the panel removal tool between the door panel and door frame. Work around the perimeter of the panel, releasing each push-pin style retaining clip. Apply outward pressure gently to avoid breaking clips. There are typically 8-12 clips around the perimeter. Lift the panel upward at the bottom edge to disengage from the window sill, then pull away from door.
4. 4

   Peel back vapor barrier
   Carefully peel back the plastic vapor barrier sheet to expose the window regulator mechanism. Start at one corner and work slowly to preserve the adhesive. If adhesive is damaged or torn, plan to replace with new vapor barrier tape during reassembly. Fold the barrier away from the work area and secure with masking tape if needed.
5. 5

   Support and secure window glass
   With the window in mid-travel position, place masking tape across the top of the glass to the door frame to support it, or have an assistant hold the glass. The window must be supported before disconnecting the regulator to prevent it from dropping into the door cavity.
6. 6

   Disconnect window regulator electrical connector
   Locate the window regulator motor electrical connector inside the door cavity. Press the locking tab and disconnect the connector from the motor. Note the routing of the wiring harness for proper reinstallation.
7. 7

   Disconnect window glass from regulator
   Locate the bolts or clips securing the window glass to the regulator lift channel or carrier. These are typically accessed through service holes in the door frame. Use the 10mm socket to remove the fasteners connecting the glass to the regulator. Once disconnected, carefully lift the window glass up and secure it in the fully raised position with additional tape.
8. 8

   Remove window regulator mounting fasteners
   Using the T30 Torx driver and 10mm socket as needed, remove all bolts securing the window regulator assembly to the door frame. The regulator is typically held by 4-6 bolts at various locations. Note the position and length of each bolt as they may differ. Support the regulator assembly as you remove the final fasteners.
9. 9

   Extract regulator assembly from door
   Carefully maneuver the window regulator assembly through the largest service opening in the door frame. The regulator may need to be rotated or angled to clear obstructions. If equipped with a cable-style regulator, ensure cables do not snag on door structure during removal. Inspect the removed regulator for signs of failure such as broken cables, stripped gears, or damaged motor.
10. 10

    Prepare and install new regulator
    Unpack the new window regulator and compare it to the old unit to confirm correct application. Route the new regulator assembly into the door cavity through the service opening. Align mounting holes and thread bolts by hand before tightening. Position the regulator so that the lift mechanism will properly align with the window glass mounting points.
11. 11

    Secure new regulator mounting bolts
    Install all window regulator mounting bolts and tighten in a cross-pattern sequence using the T30 Torx driver and 10mm socket. Ensure the regulator assembly sits flush against the door frame at all mounting points. Verify that the regulator moves freely through its full range of motion before proceeding.
12. 12

    Reconnect window glass to regulator
    Remove the tape securing the window glass. Lower the glass carefully until the mounting points align with the regulator lift channel. Insert and tighten the fasteners securing the glass to the regulator using the 10mm socket. Ensure the glass is level and properly seated in the lift channel.
13. 13

    Connect regulator electrical connector and test
    Reconnect the electrical connector to the window regulator motor. Temporarily reconnect the 12V auxiliary battery. Test window operation through full up and down travel without the door panel installed. Verify smooth operation with no binding, unusual noise, or hesitation. Check that window seals properly against weatherstripping at top of travel. Disconnect battery again before final reassembly.

Reassembly

1. Reposition and press the vapor barrier sheet firmly against the door frame, ensuring complete adhesion around all edges and service holes
2. Apply new vapor barrier adhesive tape if original adhesive was damaged during removal
3. Route the door panel wiring harness properly to avoid pinching during panel installation
4. Align the door panel at the window sill first, then press firmly around the perimeter to engage all retaining clips
5. Reconnect the door handle switch electrical connector and secure the switch assembly
6. Reinstall all T25 Torx screws around the door panel perimeter
7. Reconnect the 12V auxiliary battery negative terminal

Verification

• Operate the rear window through complete up and down cycles multiple times to verify smooth operation
• Verify window auto-up and auto-down functions operate correctly if equipped
• Check that window stops properly at full up and full down positions without over-travel
• Listen for any abnormal grinding, clicking, or binding noises during operation
• Inspect door panel fit and ensure all trim clips are fully engaged with no gaps
• Verify door handle switch assembly functions correctly
• Check window seal against weatherstripping for proper alignment and water tightness
• Perform a pinch protection test if equipped by placing a soft object in the window path during closure

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