This vehicle has experienced two separate failures of the high-voltage (HV) battery pack, each resulting in a different drive unit being damaged and total loss of electrical systems while driving. First incident (July 28, 2025): While driving, all warning lights illuminated and the vehicle indicated a possible electrical hazard. The vehicle lost power completely. It was taken to a Rivian service center on July 29, 2025, and was not returned until August 15, 2025 — a total of 17 days out of service. Rivian’s technicians found multiple faults in the HV battery pack and replaced it. Rivian’s own repair notes state that its engineering team requested the front drive unit also be replaced “due to the nature of the failure with the HV battery pack” — i.e., Rivian attributed the drive unit damage to the battery pack failure, not to an independent defect. Both the HV battery pack and front drive unit were replaced under warranty. Second incident (June 29, 2026, approx. 16,256 miles): After charging at a Tesla Supercharger, the vehicle displayed a “Rivian thermal system fault” warning, which indicated driving could continue. While subsequently driving on the highway, the vehicle displayed a “reduced performance” warning, followed by an “all-wheel drive system fault” warning. A loud popping sound was then heard from the rear drive unit, accompanied by visible and smell of smoke in the vehicle. The driver safely pulled over. All electrical systems malfunctioned in the same manner as the first incident. The vehicle is currently undergoing diagnosis; based on the symptoms (identical to the first incident) and Rivian’s own causal link between battery failure and drive unit damage in the first incident, it is possible the HV battery pack is again involved, this time in connection with the rear drive unit.
NHTSA ODI 11747254