This procedure covers replacement of the front axle seal on a 2019-2024 Toyota RAV4 2.5L FWD, requiring removal of the front axle shaft to access and replace the transaxle seal.

Warnings

Tools required

Parts

• Front axle seal × 1 — Use OEM Toyota transaxle seal for 2019-2024 RAV4
• Axle nut × 1 — 90178-26029 or equivalent
• Cotter pin for axle nut × 1 — Only if axle nut uses cotter pin instead of stake

Fluids

• Toyota WS ATF — 1.5 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Loosen wheel lug nuts on the side being serviced while vehicle is on the ground
3. With vehicle on ground and brakes applied, use breaker bar and 30mm socket to break loose the front axle nut (do not remove completely yet)
4. Raise vehicle and support securely on jack stands at manufacturer-specified lift points
5. Remove wheel completely
6. Place drain pan under transaxle area to catch ATF spillage

Procedure

1. 1

   Remove axle nut and washer
   With wheel removed and vehicle supported, completely remove the 30mm axle nut that was previously loosened. Remove the washer behind the nut. Discard the old axle nut as it must be replaced with a new one.
2. 2

   Separate lower ball joint from knuckle
   Remove the pinch bolt securing the lower ball joint to the steering knuckle. Use a ball joint separator tool to separate the lower control arm ball joint from the knuckle. Do not damage the ball joint boot during separation.
3. 3

   Push axle shaft through wheel hub
   Pull the steering knuckle assembly outward while pushing the axle shaft inward through the wheel hub. The splined end of the axle should push back through the hub bearing. If the axle is seized in the hub, use a brass drift to carefully tap it through from the outer end.
4. 4

   Remove axle shaft from transaxle
   Using a pry bar positioned between the transaxle case and the inner CV joint, carefully pry the axle shaft out of the transaxle. Pull the entire axle assembly out of the vehicle. ATF will drain from the transaxle opening. If the axle is difficult to remove, use a slide hammer with axle puller adapter. Be careful not to damage the seal bore.
   ⚠Pry only against the inner CV joint housing, not the axle shaft itself. Prying against the shaft can damage it.
5. 5

   Remove old axle seal
   Using a seal puller or seal removal tool, carefully extract the old axle seal from the transaxle housing. Work carefully to avoid scoring or damaging the seal bore in the aluminum transaxle case. Clean the seal bore thoroughly with a clean rag and inspect for damage or burrs.
6. 6

   Install new axle seal
   Lightly coat the outer diameter of the new seal with clean ATF. Position the seal squarely in the bore with the seal lip facing inward toward the transmission. Using a seal driver or large socket that contacts only the outer edge of the seal, carefully drive the seal into the bore until it is fully seated and flush with the transaxle case. Ensure the seal is installed straight and not cocked.
   ⚠Never strike the seal face directly. Only apply force to the outer metal rim to prevent seal damage.
7. 7

   Inspect axle shaft and CV joint
   Before reinstallation, inspect the axle shaft splines and the area that contacts the seal for damage, burrs, or excessive wear. Check CV joint boots for tears or damage. Clean the seal contact area on the axle shaft with a rag. Light surface rust can be cleaned with a wire brush.
8. 8

   Reinstall axle shaft into transaxle
   Apply a light coat of clean ATF to the seal lip and axle shaft seal contact area. Carefully align the inner CV joint with the transaxle opening and push the axle shaft straight in. You should feel the circlip on the inner CV joint snap into place. Pull outward on the axle to confirm it is properly seated and retained by the circlip.
9. 9

   Install axle shaft through wheel hub
   Pull the steering knuckle outward and guide the outer splined end of the axle shaft through the wheel hub bearing. Ensure the splines fully engage through the hub.
10. 10

    Reconnect lower ball joint
    Position the lower control arm ball joint into the steering knuckle. Install and tighten the pinch bolt to secure the ball joint to the knuckle.
11. 11

    Install new axle nut
    Install the washer and new 30mm axle nut onto the axle shaft. Do not torque yet. Hand-tighten the nut to hold components in place.
12. 12

    Reinstall wheel and lower vehicle
    Install the wheel and hand-tighten the lug nuts. Lower the vehicle until the tire just contacts the ground but the weight is still supported by the jack. Torque the lug nuts to specification in a star pattern. Then lower the vehicle completely to the ground.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
13. 13

    Torque axle nut and stake
    With the vehicle on the ground and brakes applied, torque the axle nut to 250 Nm (184 lb-ft) using a torque wrench and 30mm socket. After torquing, stake the nut into the groove on the axle shaft using a punch and hammer, or install a new cotter pin if your vehicle uses that style of retention. Verify the nut is secure.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
14. 14

    Refill transmission fluid
    Check the transmission fluid level using the proper procedure for the RAV4 (typically requires warming the transmission to operating temperature and checking through the fill plug). Add Toyota WS ATF as needed to bring the level to specification. Approximately 1-1.5 quarts may have been lost during the procedure.

Reassembly

1. Ensure the axle nut is properly staked or cotter pin is installed to prevent loosening
2. Verify all fasteners have been reinstalled and properly torqued
3. Double-check that no tools or rags were left in the work area

Verification

• Start the engine and shift through all gears to circulate ATF
• Inspect the axle seal area for any signs of leakage with the engine running
• Take a short test drive and recheck the seal area for leaks
• Verify the transmission fluid level is correct after the vehicle reaches operating temperature
• Check for any unusual noises from the CV joint or wheel bearing during the test drive

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