This procedure replaces both front strut assemblies on a 2019-2024 Toyota RAV4 with 2.5L I4 engine, including removal of the complete strut assembly and installation of new strut units.

Warnings

Tools required

Parts

• Front strut assembly (complete) × 2 — Use OEM specification or equivalent complete strut assembly
• Strut tower mounting nuts (if corroded) × 6 — M10 flange nuts
• Sway bar link (if worn or damaged) × 2 — Inspect and replace as needed

Preparation

1. Park vehicle on level, solid ground 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 designated lift points
5. Support vehicle with jack stands under frame rails behind front wheels
6. Remove both front wheels completely
7. Spray all suspension fasteners with penetrating oil and allow to soak for 10-15 minutes
8. Ensure you have complete strut assemblies ready (if not disassembling and reassembling original struts)

Procedure

1. 1

   Disconnect sway bar link from strut
   Locate the sway bar link connecting to the strut assembly. Insert a 6mm Allen key into the shaft end to prevent rotation. Using a 14mm socket, remove the upper nut connecting the sway bar link to the strut. The link will remain attached to the sway bar. If the ball joint spins, replace the link.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
2. 2

   Remove brake line bracket from strut
   Locate the brake line bracket mounted to the strut body. Remove the single bolt securing the bracket using a 10mm socket. Carefully move the brake line aside to prevent strain. Do not disconnect or damage the brake line itself.
   ⚠Do not kink, stretch, or damage the brake line. Support it to prevent stress on connections.
3. 3

   Remove strut-to-knuckle bolts
   Locate the two horizontal bolts connecting the bottom of the strut to the steering knuckle. These are large 19mm bolts. Support the strut assembly with one hand or have an assistant hold it. Remove both bolts completely using a 19mm socket and breaker bar. The strut will now be free at the bottom but still attached at the top.
   ⚠Support the strut assembly before removing the second bolt to prevent it from falling.
   Torque spec

   Strut Bolts115 Nm (85 lb-ft)
4. 4

   Access strut tower mounting nuts
   Open the hood. Locate the strut tower in the engine compartment directly above the strut assembly. Remove any plastic cowl covers or engine covers if they obstruct access to the three mounting nuts on top of the strut tower.
   ℹ️On the driver side, you may need to move the fuse box or washer reservoir aside for better access.
5. 5

   Remove strut tower mounting nuts
   While supporting the strut assembly from below, use a 14mm socket to remove the three nuts securing the strut to the strut tower. Keep track of any washers or insulators. Once all three nuts are removed, carefully lower the strut assembly down and out of the wheel well.
   ⚠Have an assistant support the strut from below, or use a floor jack under the lower control arm to support the assembly during removal.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
6. 6

   Inspect and transfer components if needed
   If installing complete strut assemblies, proceed to installation. If reusing components from the old strut, use spring compressors to safely disassemble the old strut. Transfer the spring, upper mount, bearing plate, and bump stop to the new strut cartridge. Ensure the spring is properly seated in the upper and lower perches.
   ⚠️Only use properly rated spring compressors. Compress the spring evenly on opposite sides. Never place any body part in the path of a compressed spring. Follow spring compressor manufacturer instructions exactly.
7. 7

   Install new strut assembly into strut tower
   Position the new strut assembly into the wheel well from below. Align the three studs on the upper mount with the holes in the strut tower. Ensure any alignment marks or tabs are properly oriented. Push the studs through the strut tower.
   ℹ️The upper mount has a specific orientation. The mounting studs should align naturally if the strut is oriented correctly.
8. 8

   Install strut tower mounting nuts
   From the engine compartment, install the three upper mounting nuts with any washers or insulators in their original positions. Thread nuts by hand first to ensure proper threading. Torque all three nuts to specification using a torque wrench.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
9. 9

   Connect strut to steering knuckle
   Align the strut bracket with the mounting holes in the steering knuckle. You may need to use a pry bar to align the holes. Insert both strut-to-knuckle bolts from the front. Install nuts on the rear side and torque to specification. Ensure the knuckle is fully seated against the strut bracket.
   ℹ️The bolts have an eccentric cam washer that affects alignment. Mark the original position before removal, or expect to need an alignment afterward.
   Torque spec

   Strut Bolts115 Nm (85 lb-ft)
10. 10

    Reattach brake line bracket
    Position the brake line bracket back onto the strut body. Install the mounting bolt and tighten securely. Ensure the brake line is properly routed and not kinked or stretched.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
11. 11

    Reconnect sway bar link
    Align the sway bar link ball stud with the hole in the strut bracket. Install the nut and insert a 6mm Allen key into the shaft to prevent rotation. Torque the nut to specification while holding the Allen key.
    ℹ️If the ball joint spins freely and cannot be held with the Allen key, the link is worn and must be replaced.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)
12. 12

    Repeat for opposite side
    Repeat steps 1 through 11 for the other front strut assembly. Ensure all fasteners are torqued to specification on both sides.
13. 13

    Install wheels and lower vehicle
    Reinstall both front wheels. Thread lug nuts by hand to prevent cross-threading. Snug lug nuts in a star pattern but do not fully torque yet. Carefully lower the vehicle until the wheels just contact the ground. Torque all lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Double-check that all fasteners have been installed and torqued to specification
2. Verify brake lines are properly routed and secured with no kinks or damage
3. Reinstall any engine covers or cowl panels removed for access
4. Close hood and remove wheel chocks

Verification

• Test drive vehicle in a safe area at low speed. Listen for any unusual noises, clunks, or rattles from the front suspension
• Check that steering response is normal and vehicle tracks straight (before alignment)
• Verify no fluid leaks from brake lines
• Schedule a professional four-wheel alignment immediately. New struts will affect camber and toe settings
• After 50-100 miles, re-torque all suspension fasteners to specification as settling may occur
• Visually inspect all fasteners for proper torque and ensure nothing has loosened

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