This procedure covers the removal and replacement of the upper and lower ball joints on the front suspension of a 2019-2024 Toyota RAV4 with the 2.5L I4 engine.

Warnings

Tools required

Parts

• Upper ball joint × 2 — Use OEM specification or quality aftermarket
• Lower ball joint × 2 — Use OEM specification or quality aftermarket
• Cotter pins for ball joint nuts × 4 — Use OEM specification
• Pinch bolt (lower ball joint) × 2 — New fastener required

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, but do not remove
4. Raise front of vehicle with floor jack and support securely on jack stands under the frame rails
5. Remove front wheels completely
6. Spray all ball joint nuts, pinch bolts, and control arm fasteners with penetrating oil and allow to soak

Procedure

1. 1

   Disconnect sway bar link
   Locate the sway bar link connected to the lower control arm. Hold the shaft with an Allen key to prevent rotation and remove the lower sway bar link nut. Disconnect the sway bar link from the control arm and secure it out of the way.
2. 2

   Remove lower ball joint pinch bolt
   Locate the pinch bolt that secures the lower ball joint to the steering knuckle. This is a single horizontal bolt that clamps the ball joint stud. Remove and discard this bolt as a new one will be installed. Note that the bolt passes through a pinch clamp on the knuckle.
3. 3

   Separate lower ball joint from knuckle
   Use a pry bar or ball joint separator to spread the pinch clamp slightly and release the lower ball joint stud from the steering knuckle. You may need to tap the knuckle with a hammer while prying to free the taper. Once separated, allow the lower control arm to drop down slightly.
   ⚠Do not over-spread the pinch clamp or use excessive force as this can crack the steering knuckle.
4. 4

   Access upper ball joint
   Locate the upper ball joint nut at the top of the steering knuckle. Remove the cotter pin using pliers or a cotter pin tool and discard it. Using a 19mm socket, loosen but do not fully remove the upper ball joint nut. Leave it threaded on a few turns to catch the knuckle when the joint separates.
5. 5

   Separate upper ball joint
   Use a ball joint separator tool or pickle fork to separate the upper ball joint stud from the steering knuckle. Once the taper releases, remove the nut completely. The steering knuckle and hub assembly can now be maneuvered for access. Support the knuckle to prevent strain on the brake line and CV axle.
   ⚠Do not allow the knuckle assembly to hang by the brake hose or CV axle. Support with wire or a bungee cord.
6. 6

   Remove lower ball joint from control arm
   With the lower ball joint freed from the knuckle, use a ball joint press kit or take the control arm to a shop with a hydraulic press. Press the old lower ball joint out of the control arm. Clean the ball joint bore thoroughly with a wire brush, removing all rust and debris.
7. 7

   Remove upper ball joint from control arm
   The upper ball joint is pressed into the upper control arm. Using a ball joint press or hydraulic press, remove the old upper ball joint from the control arm. Note the orientation and depth of the original ball joint. Clean the bore completely with a wire brush.
8. 8

   Install new lower ball joint
   Using the ball joint press kit, press the new lower ball joint into the lower control arm. Ensure the ball joint is pressed in squarely and to the correct depth, typically flush with the control arm surface or as specified by the ball joint manufacturer. Do not use heat or hammers to install.
9. 9

   Install new upper ball joint
   Press the new upper ball joint into the upper control arm using the ball joint press. Ensure proper orientation and press depth. The ball joint must be fully seated and aligned correctly for proper operation.
10. 10

    Connect upper ball joint to knuckle
    Guide the steering knuckle back into position and insert the upper ball joint stud into the knuckle. Install the upper ball joint nut and torque according to specification. Install a new cotter pin through the castle nut and ball joint stud, bending the ends to secure.
    ℹ️If the cotter pin holes do not align, tighten the nut further up to the next alignment point. Never loosen to align.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
11. 11

    Connect lower ball joint to knuckle
    Position the lower control arm so the lower ball joint stud enters the steering knuckle pinch clamp. Ensure the stud is fully seated in the taper. Install a new pinch bolt and torque to specification.
    Torque spec

    Pinch Bolt61 Nm (45 lb-ft)
12. 12

    Reconnect sway bar link
    Reconnect the sway bar link to the lower control arm. Hold the shaft with an Allen key and install the nut. Torque the sway bar link nut to specification.
    Torque spec

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

    Install wheels and lower vehicle
    Install the front wheels and hand-tighten the lug nuts. Lower the vehicle until the tires just contact the ground but the suspension is not fully loaded. Torque the wheel lug nuts to specification in a star pattern. Then fully lower the vehicle to the ground.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
14. 14

    Final torque control arm bolts with weight on wheels
    With the vehicle on the ground and suspension at normal ride height, torque all control arm mounting bolts to specification. This critical step ensures the control arm bushings are torqued in their normal operating position, preventing premature wear.
    ⚠Failure to torque control arm bolts with vehicle weight on wheels will cause premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Repeat all steps for the opposite side if replacing both sides
2. Ensure all torque specifications have been met with proper torque wrench
3. Verify all cotter pins are properly installed and bent
4. Check that all fasteners are tight and no tools or parts have been left in the wheel well

Verification

• Test drive the vehicle at low speed in a safe area and verify no unusual noises or vibrations
• Perform a visual inspection of all connections to ensure nothing is loose
• Have the front end alignment checked and adjusted by a qualified shop as ball joint replacement will affect alignment settings
• After 50-100 miles, re-torque all fasteners and verify nothing has loosened

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