This procedure covers replacement of the front lower control arm bushings on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine, which typically requires removing the control arm from the vehicle.

Warnings

Tools required

Parts

• Front lower control arm bushing kit × 2 — Use OEM specification or aftermarket equivalent
• Cotter pin (if equipped) × 2 — 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 (do not remove)
4. Raise front of vehicle with floor jack at manufacturer's jacking points
5. Support vehicle securely on jack stands placed at frame rails or designated support points
6. Remove front wheels completely

Procedure

1. 1

   Apply penetrating oil
   Spray penetrating oil on the ball joint nut, control arm mounting bolts, and any other fasteners that will be removed. Allow to soak for 10-15 minutes if fasteners show corrosion.
2. 2

   Remove ball joint cotter pin
   If equipped with a cotter pin on the ball joint castle nut, straighten the legs and remove the cotter pin using pliers or a cotter pin removal tool. Discard the old cotter pin.
3. 3

   Remove ball joint nut
   Using a 17mm wrench and socket, remove the ball joint castle nut from the lower control arm ball joint stud. Keep the nut accessible as it may be needed to help separate the joint.
4. 4

   Separate ball joint from knuckle
   Use a ball joint separator tool or pickle fork to separate the lower control arm ball joint from the steering knuckle. Insert the tool between the control arm and knuckle, then tighten or strike as appropriate for your tool type. The ball joint should pop free. Support the control arm once separated to prevent sudden dropping.
   ⚠Control arm will drop once ball joint separates. Keep hands and tools clear of pinch points.
5. 5

   Remove front control arm bolt
   Locate the front control arm mounting bolt that connects the control arm to the front subframe. Using an 18mm socket and wrench, remove the bolt completely while supporting the control arm. This is the smaller mounting point closer to the front of the vehicle.
6. 6

   Remove rear control arm bolt
   Locate the rear control arm mounting bolt that connects the control arm to the rear subframe bracket. Using an 18mm socket and wrench, remove this bolt completely. The control arm can now be removed from the vehicle.
7. 7

   Remove control arm from vehicle
   Pull the control arm out of the mounting points and remove it from the vehicle. Inspect the ball joint for wear or damage while the arm is out. Clean the control arm mounting surfaces on the subframe with a wire brush.
8. 8

   Press out old bushings
   Using a hydraulic press or control arm bushing removal tool, press out the old bushings from the control arm. Note the orientation of each bushing before removal. The bushings may have offset centers or directional features that must be matched during installation. Clean the bushing bores thoroughly with a wire brush.
   ⚠Wear safety glasses when using a press. Bushings may release suddenly under pressure.
9. 9

   Install new bushings
   Apply a light coating of soapy water or bushing installation lubricant to the new bushings (not grease or oil). Align the new bushings in the correct orientation matching the old bushings. Using the hydraulic press or installation tool, press the new bushings into the control arm bores until fully seated and flush with the control arm housing.
10. 10

    Install control arm to subframe
    Position the control arm with new bushings into the front and rear mounting points on the subframe. Insert both control arm mounting bolts finger-tight only. Do not torque at this time. Ensure the control arm moves freely on the bolts.
11. 11

    Connect ball joint to knuckle
    Lift the control arm and align the ball joint stud with the hole in the steering knuckle. A pry bar may be needed to align the holes. Install the ball joint castle nut and tighten to specification using a 17mm socket and torque wrench. If equipped with a cotter pin, install a new cotter pin through the castle nut and ball joint stud, then bend the legs to secure.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
12. 12

    Install wheels and lower vehicle
    Install the front wheels and thread the lug nuts on by hand. Lower the vehicle carefully onto the jack stands so the suspension is at normal ride height with the vehicle weight on the wheels, but the vehicle is still safely supported. The tires should be touching the ground with full vehicle weight.
13. 13

    Torque control arm bolts at ride height
    With the vehicle at normal ride height and weight on the suspension, torque both the front and rear control arm mounting bolts to specification using an 18mm socket and torque wrench. This is critical - torquing these bolts with the suspension hanging will cause premature bushing failure.
    ⚠Control arm bolts MUST be torqued with vehicle weight on suspension at normal ride height.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
14. 14

    Final wheel installation
    Raise the vehicle completely off the ground and remove jack stands. Lower the vehicle to the ground. Torque all wheel lug nuts to specification in a star pattern using a 19mm socket and torque wrench.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification
2. Verify cotter pins are properly installed and secured on ball joints if equipped
3. Double-check that control arm bolts were torqued at normal ride height, not with suspension hanging

Verification

• Test drive the vehicle at low speed and verify no clunking or unusual noises from the front suspension
• Perform a visual inspection under the vehicle to confirm all bolts are tight and properly installed
• Schedule a front-end alignment as suspension geometry may have changed during the repair
• Re-torque wheel lug nuts after 50-100 miles of driving

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