This procedure covers the replacement of the front strut air spring/air bag on a 2019-2024 Toyota RAV4 with 2.5L I4 FWD engine.

Warnings

Tools required

Parts

• Front strut mount assembly (if damaged) × 1 — Use OEM specification
• Strut dust boot (if damaged) × 1 — Use OEM specification
• Bump stop (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen front wheel lug nuts before raising vehicle
3. Raise front of vehicle and support securely on jack stands placed at manufacturer-recommended jacking points
4. Remove front wheel on side being serviced
5. Spray penetrating lubricant on strut mounting nuts and bolts, allow to soak

Procedure

1. 1

   Access strut tower mounting nuts
   Open hood and locate the three strut tower mounting nuts at the top of the strut assembly. These are accessible from the engine bay. Clean area around nuts to prevent debris from falling into strut tower during removal.
2. 2

   Disconnect sway bar link
   Locate the sway bar link connection to the strut. Hold the shaft with an Allen key to prevent rotation, then remove the upper nut connecting the sway bar link to the strut. The link can remain attached to the sway bar.
   ℹ️If the ball joint stud spins, use a 6mm Allen key from below to hold it while turning the nut.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
3. 3

   Disconnect brake line bracket
   Remove the brake line bracket mounting bolt from the strut assembly. Do not disconnect the brake hose itself; simply free it from the strut to allow removal. Support the brake line to prevent stress on the connection.
4. 4

   Remove strut-to-knuckle bolts
   Locate the two bolts connecting the bottom of the strut to the steering knuckle. Support the strut assembly from below with a jack or have an assistant support it. Remove both bolts completely. You may need to rotate the steering to improve access.
   ⚠Support the strut before removing these bolts to prevent it from falling.
   Torque spec

   Strut Bolts115 Nm (85 lb-ft)
5. 5

   Separate strut from knuckle
   Pull the steering knuckle outward to separate it from the strut. You may need to use a pry bar or tap the knuckle with a rubber mallet to break the connection. The knuckle will remain connected to the ball joint and can hang from the control arm.
6. 6

   Remove strut tower nuts
   From the engine bay, remove the three nuts securing the strut mount to the strut tower. Have an assistant support the strut assembly from below, or use a floor jack under the lower control arm. Once nuts are removed, carefully lower the strut assembly out through the wheel well.
   ⚠The strut assembly is heavy. Ensure it is properly supported before removing the final nut.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
7. 7

   Inspect and replace air spring components
   With the strut removed, inspect the air spring/air bag, strut mount, dust boot, and bump stop for damage. If only replacing the mount assembly or dust boot, these can be accessed without compressing the spring. Mark the orientation of components before disassembly for proper reassembly.
   ⚠️If full strut disassembly is required, use a proper spring compressor and follow manufacturer instructions. Never attempt to disassemble a strut without compressing the spring first.
8. 8

   Install new components
   Install the new air spring/air bag, mount, dust boot, or other components as needed. Ensure all parts are properly seated and aligned according to the orientation marks made during disassembly. Verify that the spring seat is correctly positioned.
9. 9

   Reinstall strut assembly
   Lift the strut assembly into position through the wheel well. Align the mounting studs with the holes in the strut tower. Install the three strut tower nuts finger-tight first, then torque to specification. Ensure the strut mount is properly oriented with the alignment mark facing forward.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
10. 10

    Reconnect strut to knuckle
    Push the steering knuckle back onto the strut. Align the bolt holes and install both strut-to-knuckle bolts. Torque bolts to specification. Ensure the knuckle is fully seated against the strut before tightening.
    Torque spec

    Strut Bolts115 Nm (85 lb-ft)
11. 11

    Reconnect brake line bracket
    Reattach the brake line bracket to the strut assembly using the mounting bolt. Ensure the brake line is properly routed and not twisted or kinked.
12. 12

    Reconnect sway bar link
    Reconnect the sway bar link to the strut. Hold the shaft with an Allen key while tightening the nut to the specified torque value.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
13. 13

    Reinstall wheel and lower vehicle
    Install the wheel and hand-tighten lug nuts in a star pattern. Lower the vehicle until the tire just touches the ground. Torque lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification
2. Verify brake line is properly secured and not damaged
3. Check that all components are properly seated and aligned
4. If both sides were serviced, repeat verification steps for both sides

Verification

• Start the vehicle and turn the steering wheel lock-to-lock to verify no binding or unusual noises
• Perform a test drive at low speed to check for abnormal noises, vibrations, or handling issues
• Visually inspect the work area for any loose fasteners or improperly routed components
• Schedule a professional wheel alignment to ensure proper vehicle handling and tire wear
• Re-torque wheel lug nuts after 50-100 miles of driving

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