This procedure covers the removal and replacement of a front CV axle on a 2019-2024 Toyota RAV4 with the 2.5L I4 gas engine and front-wheel drive.

Warnings

Tools required

Parts

• CV Axle Assembly × 1 — Use OEM specification for side being replaced
• Axle Nut × 1 — New nut required if staking type
• Cotter Pin × 1 — If applicable to axle nut style
• Transmission Oil Seal × 1 — Recommended if seal shows wear

Fluids

• Toyota WS ATF — 1 qt

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen the front axle nut using a 32mm or 35mm socket and breaker bar while vehicle is still on the ground with wheel installed (do not remove completely)
4. Loosen wheel lug nuts slightly while vehicle is on the ground
5. Raise front of vehicle and support securely on jack stands at manufacturer-specified lift points
6. Remove the front wheel on the side being serviced

Procedure

1. 1

   Remove axle nut
   Completely remove the previously loosened front axle nut. If equipped with a staked nut, use a chisel or punch to un-stake the nut from the axle groove before removal. Set aside and do not reuse.
2. 2

   Disconnect lower ball joint
   Remove the cotter pin (if equipped) from the lower ball joint castle nut. Remove the ball joint nut or pinch bolt (depending on suspension configuration). Use a ball joint separator tool or pickle fork to separate the lower control arm from the steering knuckle. Do not damage the ball joint boot.
   ⚠Using a pickle fork may damage the ball joint boot. Use a proper ball joint separator if the joint will be reused.
3. 3

   Push axle out of wheel hub
   With the ball joint disconnected, push the outer CV joint stub shaft out of the wheel hub/bearing assembly. You may need to tap the end of the axle with a soft hammer or use a puller tool if the axle is stuck in the hub splines. Support the brake assembly and knuckle with wire or a bungee cord to prevent stress on the brake hose.
4. 4

   Position drain pan
   Place a drain pan under the transmission area where the inner CV joint connects to the transaxle. Transmission fluid will drain out when the axle is removed.
5. 5

   Remove inner CV joint from transmission
   Insert a pry bar between the inner CV joint housing and the transmission case. Pry the axle out with firm, even pressure. The CV axle will pop out of the differential side gear. Pull the entire axle assembly out from the vehicle. Be careful not to damage the transmission seal during removal.
   ⚠Do not pry against the transmission case in a way that could crack or damage the housing. Use only the designated pry points.
6. 6

   Inspect transmission seal
   Inspect the differential oil seal for damage, leaks, or excessive wear. If the seal shows any signs of damage or has high mileage, replace it now while the axle is removed. Clean the seal mating surface with a wire brush.
7. 7

   Prepare new CV axle
   Remove the new CV axle from its packaging. Verify it matches the old axle in length and spline configuration. Check that the circlip on the inner CV joint is properly seated in its groove and is not damaged. Lightly lubricate the axle splines and seal contact area with transmission fluid.
8. 8

   Install new CV axle into transmission
   Carefully align the inner CV joint with the differential side gear opening. Push the axle straight in with firm pressure until you hear and feel the circlip snap into place. Tug on the inner joint to verify it is fully seated and locked in position.
9. 9

   Install outer CV joint into hub
   Guide the outer CV joint stub shaft through the wheel hub/bearing assembly. Ensure the splines are properly aligned and push the axle through until it is fully seated. The axle should slide through relatively easily if aligned correctly.
10. 10

    Reconnect lower ball joint
    Position the lower control arm ball joint back into the steering knuckle. Install the ball joint nut or pinch bolt and tighten to specification. If using a castle nut, install a new cotter pin and bend the ends to secure.
    Torque spec

    Ball Joint Nut102 Nm (75 lb-ft)

    Ball Joint Pinch Bolt55 Nm (41 lb-ft)
11. 11

    Install and torque axle nut
    Install the new axle nut onto the CV axle stub shaft. With the vehicle still on jack stands and brakes applied (or use a pry bar to prevent rotation), torque the axle nut to specification. After torquing, stake the nut into the axle shaft groove using a punch and hammer, or install a new cotter pin if that style is used.
    ℹ️The axle nut must be properly staked or pinned to prevent loosening. Follow the specific securing method for your axle type.
    Torque spec

    Axle Nut244 Nm (180 lb-ft)
12. 12

    Reinstall wheel
    Install the wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle to the ground and torque the lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
13. 13

    Check and refill transmission fluid
    Check the transmission fluid level according to the manufacturer's procedure. Add Toyota WS ATF as needed to replace the fluid lost during axle removal. Typically 0.5-1 quart will be needed.

Reassembly

1. Ensure all fasteners are torqued to specification
2. Verify the axle nut is properly staked or pinned
3. Confirm transmission fluid is at the proper level
4. Double-check that the inner CV joint circlip is fully engaged in the differential

Verification

• Test drive the vehicle and listen for clicking or popping noises during turns, which would indicate improper CV joint installation
• Verify no vibration is present during acceleration
• Check for transmission fluid leaks around the axle seal area after test drive
• Confirm steering operates smoothly with no binding
• Re-check axle nut torque after 50-100 miles of driving

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