RCA-38-23-003-2

RCA-38-23-003-2: Replace Drive Unit Plugs, R1T and R1S
Rivian is initiating a customer satisfaction campaign for some model year 2022 R1T and R1S vehicles that may
have been built with drive units that have fastener threads on a plug sealing surface which may result in damage
to the plug o-ring and an inadequate sealing surface. This condition could allow drive unit fluid to leak from the
drive unit. Fluid leaking from the drive unit may be noticeable to the customer (though any potential leak would
be a very small amount that would not impact other road users). If the leaking occurs over an extended period
of time, it may lead to a decreased life for the drive unit and eventual failure of the drive unit. A failure of a drive
unit will result in a reduced performance safe-state mode and a corresponding indicator light will illuminate on
the driver display. Rivian will inspect each drive unit on all affected vehicles and will either install a new drive
unit plug with an enlarged washer to ensure proper sealing or replace the drive unit. Rivian is launching this
campaign for customer satisfaction and to ensure the quality of Rivian vehicles.
Note: This document supersedes RCA-38-23-003-1. Revision 2 updates the minimum volume of
drained fluid required to replace the front drive unit.
Document Type
Customer Satisfaction Campaign
Bulletin
Date
July 19, 2023
Affected Region(s)
USA
Affected Model(s)
R1T, R1S
Model Year(s)
2022
Approximate Build Dates
August 2021 - February 2022
Refer to Open Containments in ServiceOS to
determine if this document applies to a specific
vehicle.
Vehicle System
38 - Front Drive Unit
Minimum Service Location
Service Center
Potentially Required Parts
Part Number
Quantity Engineering Name
Service Name/Notes
PT00576928-A
2
PLUG M22X1.5
PT00576929-A
2
WASHER FLAT M22
SC00006385-A
2
NUT - M12X1.75 HX FL PTM CL10 R107G
Refer to the
parts catalog
for part number
and inventory
information.
1
Drive Unit, Front
Refer to the
parts catalog
for part number
and inventory
information.
1
Drive Unit, Rear
Prevailing torque
fastener. Potentially
reusable. Refer to
Fastener Reuse.
RCA-38-23-003-2: Replace Drive Unit Plugs, R1T and R1S, Page 1
Attention: The parts listed in this table are only for unique steps that are called out in this bulletin.
Some sections of this bulletin might refer to Service Manual procedures which require additional parts.
Always review the bulletin and all potentially related Service Manual procedures before ordering parts
and beginning work.
Potentially Required Special Tools:
Tool Number
Tool Name
TSN01123
Origin drive unit fill plug torque kit
Attention: The special tools listed in this table are only for unique steps that are called out in this
bulletin. Some sections of this bulletin might refer to Service Manual procedures which require
additional special tools. Always review the bulletin and all potentially related Service Manual
procedures before beginning work.
Drain and Measure Front Drive Unit Fluid
Important: This section requires measuring the amount of drive unit fluid after draining.
1. Remove: Panel, Underbody, Front Subframe (refer to service manual procedure 606515010).
2. Cut in the location(s) shown. Remove and discard:
3. Drain the front drive unit fluid into a measured container (refer to service manual procedure 381030024).
4. Measure the amount of fluid:
• If the amount of fluid is 1.1 L (1.16 qt) or less: Replace: Drive Unit, Front (refer to service manual
procedure 381010010), then skip to the Drain and Measure Rear Drive Unit Fluid and Replace Plug
section.
• If the amount of fluid is greater than 1.1 L (1.16 qt), continue to the Remove Front Drive Unit Plug
section.
RCA-38-23-003-2: Replace Drive Unit Plugs, R1T and R1S, Page 2
Remove Front Drive Unit Plug
1. On the LH side: Remove: Halfshaft, Front, LH (refer to service manual procedure 386410010).
2. On the LH side: Pull back for access:
Note: Shown with components removed for clarity.
Tip: If necessary:
Important: Attempt to remove the plug as described in the next step:
• If successful, skip to the Install New Front Drive Unit Plug section.
• If clearance is not adequate, continue to the Remove Front Drive Unit Plug (With Drive Unit
Raised) section.
RCA-38-23-003-2: Replace Drive Unit Plugs, R1T and R1S, Page 3
3. On the LH side: Using a ball-end hex bit: Remove and discard:
Note: Shown with components removed for clarity.
Remove Front Drive Unit Plug (With Drive Unit Raised)
Important: Perform this section only if the Remove Front Drive Unit Plug was unsuccessful.
1. Lower the vehicle.
2. Remove: Bin, Underhood Storage (refer to service manual procedure 647930010).
3.
1
Nut
CAUTION: Potentially nonreusable component(s).
2
Bolt
4. Raise the vehicle.
RCA-38-23-003-2: Replace Drive Unit Plugs, R1T and R1S, Page 4
5. Using an under-hoist jack stand: Support the highlighted area.
6. Slowly raise the under-hoist jack stand to provide adequate clearance for the next step.
7. On the LH side: Using a ball-end hex bit: Remove and discard:
Note: Shown with components removed for clarity.
8. Continue to the Install New Front Drive Unit Plug section.
Torque specifications in this
section
Step Number Torque (Nm)
3
90
RCA-38-23-003-2: Replace Drive Unit Plugs, R1T and R1S, Page 5
Install New Front Drive Unit Plug
1. On the LH side: Install the new plug and washer. Using the special tool: Tighten:
Note: Shown with components removed for clarity.
2. Fill the front drive unit with new fluid (refer to service manual procedure 381030024).
3. Continue to the Drain and Measure Rear Drive Unit Fluid and Replace Plug section.
Torque specifications in this
section
Step Number Torque (Nm)
1
73.5
CAUTION: This torque specification is only valid when using the special tool.
Drain and Measure Rear Drive Unit Fluid and Replace Plug
Important: This section requires measuring the amount of drive unit fluid after draining.
1. Remove: Panel, Underbody, Rear Subframe (refer to service manual procedure 606516010).
2. Cut in the location(s) shown. Remove and discard:
3. Drain the rear drive unit fluid into a measured container (refer to service manual procedure 421030024).
RCA-38-23-003-2: Replace Drive Unit Plugs, R1T and R1S, Page 6
4. Measure the amount of fluid:
• If the amount of fluid is 1.3 L (1.37 qt) or less: Replace: Drive Unit, Rear (refer to service manual
procedure 421010010). No additional work is required. Reinstall all components that were
removed for access and replace all non-reusable components. Refer to the service manual
procedures referenced in this document for additional component reusability information and
torque specifications.
• If the amount of fluid is greater than 1.3 L (1.37 qt), continue to the next step.
5. On the RH side: Pull back for access:
Note: Shown with components removed for clarity.
6. On the RH side: Remove and discard:
RCA-38-23-003-2: Replace Drive Unit Plugs, R1T and R1S, Page 7
7. On the RH side: Install the new plug and washer.
Note: Shown with components removed for clarity.
8. Fill the rear drive unit with new fluid (refer to service manual procedure 421030024).
9. Reinstall all components that were removed for access and replace all non-reusable components. Refer
to the service manual procedures referenced in this document for additional component reusability
information and torque specifications.
Torque specifications in this
section
Step Number Torque (Nm)
7
55
Labor Codes
Labor Code
Description
RCA382300300
RCA-38-23-003 not applicable
RCA382300301
Drain and measure fluid from front and rear drive units; replace front plug; replace
rear plug
RCA382300302
Drain and measure fluid from front and rear drive units; raise front drive unit;
replace front plug; replace rear plug
RCA382300303
Drain and measure fluid from front and rear drive units; replace front drive unit;
replace rear plug
RCA382300304
Drain and measure fluid from front and rear drive units; replace front plug; replace
rear drive unit
RCA382300305
Drain and measure fluid from front and rear drive units; raise front drive unit;
replace front plug; replace rear drive unit
RCA382300306
Drain and measure fluid from front and rear drive units; replace front and rear drive
units
Contact [email protected] regarding labor codes and document content.
RCA-38-23-003-2: Replace Drive Unit Plugs, R1T and R1S, Page 8