This procedure covers replacement of the inner CV boot on a 2019-2024 Toyota RAV4 2.5L I4 FWD, requiring removal of the axle assembly from the vehicle.

Warnings

Tools required

Parts

• Inner CV boot kit (includes boot, clamps, grease) × 1 — Use OEM specification
• Axle nut × 1 — 90179-36014 or equivalent
• New cotter pin (if applicable) × 1 — Use OEM specification
• CV joint grease (if not included in boot kit) × 1 — Use OEM CV grease

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts 1/4 turn while vehicle is on ground
4. Loosen (but do not remove) the axle nut while vehicle is on ground - have helper apply brakes or use breaker bar with vehicle in Park
5. Raise front of vehicle and support securely on jack stands at manufacturer-specified jacking points
6. Remove front wheel completely
7. Position drain pan under transmission area to catch any fluid spillage

Procedure

1. 1

   Remove axle nut
   Remove the center axle nut completely. If equipped with cotter pin, remove and discard it first. If staked type, use chisel to unstake before removal. This nut must be replaced with a new one during reassembly.
2. 2

   Separate lower ball joint (if needed for clearance)
   If additional clearance is needed, remove the lower ball joint pinch bolt and separate the lower control arm from the knuckle. On this model, it may be possible to proceed without this step depending on available working room.
3. 3

   Remove axle from hub
   Pull the knuckle/hub assembly outward while pushing the axle shaft inward to disengage the splines from the hub. If stuck, use a brass punch to tap the end of the axle or use a hub puller. Do not strike the threaded end directly with a steel hammer.
4. 4

   Remove axle from transmission
   Using a pry bar positioned against the transmission case and inner CV joint housing, carefully pry the axle shaft out of the transmission. Use steady pressure - the circlip will release with a pop. Pull the entire axle assembly out. Some ATF may drain; this is normal.
   ⚠Do not pry against the differential cover or you may crack it. Pry only against solid transmission case.
5. 5

   Secure axle and clean work area
   Place the axle assembly on a clean workbench. Wipe away any dirt or debris from the inner CV joint area. Clean the boot area thoroughly with a rag to prevent contamination during disassembly.
6. 6

   Remove old boot clamps
   Cut or release both inner CV boot clamps (large and small diameter). If using crimp-style clamps, cut them with side cutters. Slide the old boot away from the joint toward the center of the shaft.
7. 7

   Mark and disassemble inner CV joint
   Before removing anything, mark the relationship between the tripod housing and the tripod spider with a paint marker or scribe. Remove the housing from the tripod - it should slide off. Wipe out old grease from the housing and inspect for wear or damage.
8. 8

   Remove tripod assembly
   Remove the snap ring or circlip that retains the tripod on the axle shaft using snap ring pliers. Mark the orientation of the tripod to the shaft (or note the chamfered side). Slide the tripod assembly off the shaft. It may require light tapping with a brass punch if tight.
9. 9

   Remove old boot and clean shaft
   Slide the old boot completely off the axle shaft. Thoroughly clean the axle shaft surface where the new boot will sit using a wire brush and clean rags. Remove all old grease, dirt, and debris. Inspect the shaft for scoring or damage.
10. 10

    Install new boot and tripod
    Slide the new inner CV boot onto the axle shaft along with the new small clamp (loosely positioned). Reinstall the tripod assembly onto the shaft in the exact same orientation as removed (matching your marks). Install the new snap ring or circlip to secure the tripod.
11. 11

    Pack joint with grease and install housing
    Pack approximately half of the supplied CV grease into the tripod housing. Pack the remaining grease into and around the tripod rollers on the shaft. Slide the housing back onto the tripod, aligning your assembly marks. Ensure the housing is fully seated.
12. 12

    Position and secure boot
    Slide the boot over the CV joint housing. Ensure the boot lips are properly seated in the grooves on both the shaft and the housing. Equalize air pressure by inserting a small flat screwdriver under the boot edge briefly. Install and tighten both boot clamps using the appropriate tool per the boot kit instructions.
13. 13

    Reinstall axle into transmission
    Carefully align the inner CV joint with the transmission opening. Push firmly until you feel and hear the circlip snap into place in the differential side gear. Give the axle a firm tug outward to verify it is locked in position.
14. 14

    Reinstall axle into hub
    Guide the outer end of the axle through the hub bearing and align the splines. Push or tap the axle through until it is fully seated and the threaded end protrudes sufficiently for the axle nut. Reconnect the lower ball joint if it was separated.
15. 15

    Install new axle nut and wheel
    Install the new axle nut and tighten it hand-tight. Reinstall the wheel and thread the lug nuts on by hand. Lower the vehicle until the tire just contacts the ground (to prevent hub rotation). Torque the axle nut to specification, then stake the nut or install new cotter pin per design. Raise vehicle, torque wheel lug nuts in star pattern, then lower vehicle completely.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification
2. Verify axle nut is properly staked or cotter pin is installed and bent
3. Check that no tools or parts were left in wheel well or under vehicle
4. Verify boot clamps are tight and boot is properly seated with no twists

Verification

• Start vehicle and check for unusual noises from the front axle area
• Turn steering wheel lock-to-lock while stationary to verify no binding or clicking
• Test drive vehicle at low speed and verify smooth operation through turns
• Inspect for any transmission fluid leaks around the axle seal area
• Re-check axle nut torque after 50-100 miles of driving
• Visually inspect the new CV boot for any tears, proper seating, and secure clamps

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