This procedure covers the replacement of the front upper control arm bushings on a 2019-2024 Toyota RAV4 with the 2.5L I4 gas engine. The job requires removing the upper control arm to press out old bushings and install new ones.

Warnings

Tools required

Parts

• Front upper control arm bushing set (2 bushings per arm) × 2 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply 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 with floor jack and support securely on jack stands at manufacturer-specified lift points
5. Remove front wheel completely
6. Spray all fasteners to be removed with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Remove wheel and access upper control arm
   With the vehicle raised and supported, remove the front wheel completely. Turn the steering wheel to full lock away from the side being serviced to improve access to the upper control arm area.
2. 2

   Remove cotter pin from ball joint nut
   Locate the upper ball joint nut where the control arm connects to the steering knuckle. Straighten the cotter pin legs using needle-nose pliers or a cotter pin tool, then pull the cotter pin completely out and discard it.
3. 3

   Loosen upper ball joint nut
   Using the appropriate socket, loosen the upper ball joint nut but do not remove it completely yet. Leave it threaded on a few turns to protect the threads and prevent the control arm from suddenly separating.
4. 4

   Separate ball joint from knuckle
   Position a ball joint separator or pickle fork between the upper control arm and the steering knuckle. Apply steady pressure to separate the ball joint taper from the knuckle. Once separated, remove the ball joint nut completely. Support the knuckle to prevent strain on the brake hose and ABS sensor wire.
   ⚠Ball joint may release suddenly when taper breaks free. Keep fingers clear of pinch points.
5. 5

   Remove control arm mounting bolts
   Locate the two bolts securing the upper control arm to the chassis/subframe. These are typically located at the front and rear bushing positions. Remove both bolts completely and carefully lower the control arm away from the vehicle.
6. 6

   Inspect and mark bushing orientation
   With the control arm removed, inspect the bushings carefully. Note the orientation of any offset bushings or directional markings. Take photos or mark the control arm and bushings to ensure correct installation orientation of the new bushings.
7. 7

   Press out old bushings
   Using a hydraulic press and appropriately sized bushing removal adapters, press the old bushings out of the control arm. Apply pressure slowly and evenly. If bushings are seized, apply heat to the control arm mounting eyes (not the bushing itself) to aid removal. Clean the bushing bores thoroughly with a wire brush after removal.
   ⚠Ensure control arm is properly supported in press to prevent distortion. Do not exceed 10 tons of pressure without re-evaluating technique.
8. 8

   Install new bushings
   Apply bushing installation lubricant to the outer sleeve of the new bushings and the control arm bores. Position the new bushings in the correct orientation as noted during removal. Using the hydraulic press with proper installation adapters, press the new bushings into the control arm until fully seated and centered. Verify the bushings are not cocked or misaligned.
9. 9

   Reinstall control arm to chassis
   Position the control arm back into the mounting location on the chassis/subframe. Insert both mounting bolts and thread them in by hand. Do NOT torque these bolts yet - they must be torqued with the vehicle weight on the suspension at normal ride height.
10. 10

    Connect ball joint to knuckle
    Raise the steering knuckle into position and align the upper ball joint stud with the hole in the knuckle. You may need to use a pry bar or jack to compress the suspension slightly. Insert the ball joint stud through the knuckle and thread on the new ball joint nut.
    ℹ️Install a new cotter pin after torquing. If cotter pin holes do not align, tighten nut slightly more (never loosen to align).
    Torque spec

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

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

    Wheel Lug Nuts136 Nm (100 lb-ft)
12. 12

    Torque control arm bolts at ride height
    Lower the vehicle completely to the ground so the full weight is on the suspension. Rock the vehicle side-to-side to settle the suspension. With the vehicle at normal ride height, torque both control arm mounting bolts to specification. This is critical to prevent premature bushing failure.
    ⚠Control arm bolts MUST be torqued at ride height with vehicle weight on suspension. Torquing at full droop will cause bushing binding and premature failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification at the proper suspension position
2. Verify new cotter pin is properly installed and legs are bent to prevent removal
3. Check that no tools or parts were left in the wheel well area

Verification

• Test drive vehicle at low speed and verify no unusual noises from the front suspension
• Check for proper steering return to center and no binding through full steering range
• Schedule a front wheel alignment immediately - camber and caster will be affected by this repair
• After 50-100 miles, re-check all fastener torques and inspect for any movement or looseness

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