This procedure covers the removal and replacement of the lower ball joint on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine, including separating the ball joint from the steering knuckle and installing a new component.

Warnings

Tools required

Parts

• Lower ball joint assembly × 1 — Use OEM specification
• Ball joint castle nut × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands at manufacturer-specified jacking points
5. Remove front wheel on side being serviced

Procedure

1. 1

   Access the lower ball joint
   Locate the lower ball joint where it connects the lower control arm to the steering knuckle. The ball joint stud extends upward through the knuckle with a castle nut and cotter pin securing it from above.
2. 2

   Remove the cotter pin
   Straighten the cotter pin using pliers or a cotter pin tool, then pull it out of the castle nut. Discard the old cotter pin as a new one must be installed during reassembly.
3. 3

   Loosen the ball joint castle nut
   Using a 19mm socket, loosen but do not completely remove the castle nut from the ball joint stud. Leave the nut threaded on a few turns to prevent the control arm from dropping suddenly when the taper is broken.
4. 4

   Separate the ball joint from the knuckle
   Position the ball joint separator or pickle fork between the lower control arm and the steering knuckle at the ball joint. Strike the separator with a hammer to break the taper fit, or use a screw-type ball joint separator per the tool's instructions. Once the taper is broken, the knuckle will lift slightly from the ball joint stud.
   ⚠The control arm may spring downward when released - maintain control of the knuckle assembly
5. 5

   Remove the castle nut and support the knuckle
   Remove the castle nut completely from the ball joint stud. Support the steering knuckle and brake assembly with a wire or bungee cord to prevent strain on the brake hose and ABS sensor wire. Do not allow the knuckle to hang by the brake components.
6. 6

   Remove ball joint mounting fasteners
   Locate the ball joint mounting bolts or rivets securing the ball joint to the lower control arm. If the ball joint is bolted, remove the mounting bolts using the appropriate socket. If the ball joint is riveted, drill out the rivets using a drill bit slightly larger than the rivet shaft, being careful not to damage the control arm.
7. 7

   Remove the old ball joint
   Once all fasteners are removed, separate the ball joint from the lower control arm. Inspect the control arm mounting surface for damage, corrosion, or deformation. Clean the mounting surface with a wire brush to ensure proper seating of the new ball joint.
8. 8

   Install the new ball joint
   Position the new ball joint onto the lower control arm, aligning the mounting holes. Install the new mounting bolts (if applicable) and tighten finger-tight. If the original was riveted, the replacement will typically use bolts. Torque the ball joint mounting bolts to manufacturer specifications (typically supplied with the replacement ball joint kit).
9. 9

   Reconnect ball joint to steering knuckle
   Lower the steering knuckle onto the ball joint stud, ensuring the stud passes cleanly through the hole in the knuckle. Install the new castle nut and tighten to the specified torque. If the cotter pin holes do not align, tighten the nut further (never loosen) until the next slot aligns with the hole in the stud.
   Torque spec

   Ball Joint Nut102 Nm (75 lb-ft)
10. 10

    Install new cotter pin
    Insert a new cotter pin through the castle nut and ball joint stud. Bend the ends of the cotter pin around the nut to secure it - one end can be bent up along the nut, the other bent down or around the side. Ensure the cotter pin cannot back out.
11. 11

    Reinstall wheel and lower vehicle
    Install the wheel and thread the lug nuts by hand. Lower the vehicle until the tire just touches the ground but the suspension is not fully loaded. Torque the wheel lug nuts in a star pattern to specification.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
12. 12

    Final torque verification
    Fully lower the vehicle so the suspension is at normal ride height with vehicle weight on the wheels. Verify all fasteners are properly torqued. If control arm bolts were disturbed during the procedure, they must be torqued to specification with vehicle weight on wheels.

Reassembly

1. Always use a new cotter pin - never reuse the old one
2. If castle nut slots do not align with stud hole at specified torque, tighten further to next alignment - never loosen
3. Verify ball joint dust boot is properly seated and not damaged during installation

Verification

• Test drive vehicle at low speed and verify no unusual noises from front suspension
• Perform visual inspection of ball joint area for proper installation and secure fasteners
• Check for proper steering response and no pulling to either side
• Schedule alignment check as suspension work may affect wheel alignment settings

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