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

Warnings

Tools required

Parts

• Front CV axle assembly - driver side × 1 — Use OEM or quality aftermarket
• Front CV axle assembly - passenger side × 1 — Use OEM or quality aftermarket
• Axle nut - both sides × 2 — 90178-50066 or equivalent
• Cotter pin for ball joint nut (if equipped) × 2 — Check existing configuration

Fluids

• Toyota WS ATF — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen (but do not remove) both front axle nuts while vehicle is on ground - these require significant force
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands at manufacturer jacking points
5. Remove both front wheels
6. Place drain pan under transmission to catch fluid during axle removal

Procedure

1. 1

   Remove driver side axle nut
   Completely remove the previously loosened driver side axle nut. If equipped with a cotter pin, remove it first. If nut is staked, use a chisel or punch to unstake before removal. Discard the old axle nut as it is not reusable.
2. 2

   Disconnect driver side lower ball joint
   Remove the cotter pin (if equipped) from the lower ball joint castle nut. Remove the ball joint nut completely. Use a ball joint separator tool or pickle fork to separate the lower control arm ball joint from the steering knuckle. Avoid damaging the ball joint boot during separation.
3. 3

   Remove driver side CV axle from hub
   Push the outer CV joint and axle shaft out of the wheel hub assembly. If the axle is stuck in the hub, use a soft mallet to tap on the end of the axle shaft while pulling outward on the knuckle. Do not strike the threads. Support the outer end of the axle to prevent damage to the inner CV joint.
4. 4

   Remove driver side axle from transmission
   Using a pry bar positioned against the transmission case and the inner CV joint housing, carefully pry the axle straight out of the transmission. Apply even pressure and pull the axle assembly completely out. Transmission fluid will drain - this is normal. Immediately plug the transmission opening with a clean rag to minimize fluid loss and prevent contamination.
   ⚠Do not pry against the CV boot or you will tear it. Pry only against metal housing.
5. 5

   Remove passenger side axle
   Repeat steps 1-4 for the passenger side axle assembly. Remove the axle nut, disconnect the ball joint, extract the axle from the hub, and pry the axle out of the transmission. Plug the transmission opening to prevent excessive fluid loss.
6. 6

   Clean and inspect hubs and transmission openings
   Wire brush the hub splines to remove any rust or debris. Inspect the wheel bearing for excessive play or roughness - replace if needed. Clean the transmission seal contact areas on both axle openings. Inspect transmission seals for damage and replace if torn or leaking.
7. 7

   Install driver side axle into transmission
   Remove the rag from the transmission opening. Align the splines of the new driver side CV axle with the transmission opening. Push the axle firmly into the transmission until you feel and hear a definite click, indicating the circlip has seated. Give the axle a firm pull outward to verify it is locked in place.
8. 8

   Install driver side axle into hub and connect ball joint
   Insert the outer CV axle splines into the wheel hub, pushing it through until fully seated. Reconnect the lower ball joint to the steering knuckle. Install the new ball joint nut and torque to specification. Install a new cotter pin if equipped, or verify the nut design matches original.
   Torque spec

   Ball Joint Nut102 Nm (75 lb-ft)
9. 9

   Install driver side axle nut (preliminary)
   Install the NEW driver side axle nut and hand-tighten only at this stage. Do not torque yet. The axle nut will be torqued to final specification after the vehicle is lowered and weight is on the wheels.
10. 10

    Install passenger side axle assembly
    Repeat steps 7-9 for the passenger side axle. Install into transmission until it clicks, install into hub, reconnect ball joint, and hand-tighten the new axle nut. Verify both axles are fully seated in transmission and hubs.
    Torque spec

    Ball Joint Nut102 Nm (75 lb-ft)
11. 11

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

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

    Torque axle nuts to final specification
    With vehicle weight on the ground and parking brake engaged, torque both front axle nuts to 250 Nm (184 lb-ft). After torquing, stake the axle nut collar into the axle shaft groove using a punch and hammer, or install a new cotter pin per original equipment design. This prevents the nut from loosening.
    ℹ️Axle nut must be torqued with vehicle on ground to prevent bearing damage.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
13. 13

    Refill transmission fluid
    Check transmission fluid level using the dipstick or fill plug (depending on model year). Add Toyota WS ATF as needed to bring level to the proper range. Approximately 1-1.5 quarts will have been lost during axle removal. Start engine, shift through all gears, and recheck fluid level with engine at operating temperature.

Reassembly

1. Ensure both axle nuts are properly torqued and staked or pinned
2. Verify all ball joint nuts are torqued to specification and secured with cotter pins if applicable
3. Confirm transmission fluid level is correct after test drive

Verification

• Test drive vehicle and listen for clicking or popping noises during turns - this may indicate improper CV axle installation
• Verify no vibration at highway speeds - vibration may indicate axle imbalance or improper seating
• Check for transmission fluid leaks at both axle seals after test drive
• Recheck axle nut torque after 50-100 miles of driving
• Verify no excessive play in CV joints by attempting to move axle shafts radially while suspended

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