This procedure covers removal and installation of the front steering knuckle/spindle assembly on a 2019-2024 Toyota RAV4 with 2.5L I4 engine, including disconnection of brake, ABS, and suspension components.

Warnings

Tools required

Parts

• Front steering knuckle assembly × 1 — Use OEM specification
• Axle hub nut × 1 — 90179-36031 or equivalent
• Lower ball joint cotter pin × 1 — Use OEM specification
• ABS sensor (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
3. Loosen but do not remove the 32mm axle hub nut while vehicle is on ground with brake applied
4. Raise front of vehicle and support securely on jack stands under frame rails
5. Remove front wheel
6. Spray all suspension fasteners with penetrating oil and allow to soak

Procedure

1. 1

   Remove axle hub nut and brake caliper
   Completely remove the 32mm axle hub nut that was loosened during preparation. Remove the two brake caliper mounting bolts from the rear of the knuckle and carefully lift the caliper off the rotor. Support the caliper with wire or a hanger from the strut spring - do not let it hang by the brake hose.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
2. 2

   Remove brake rotor and ABS sensor
   Remove the brake rotor by pulling it straight off the hub (use brass hammer if stuck). Disconnect the ABS wheel speed sensor electrical connector. Remove the single bolt securing the ABS sensor to the knuckle and carefully extract the sensor from its bore. Inspect sensor for damage.
3. 3

   Disconnect sway bar link
   Locate the sway bar end link connection at the lower control arm or strut, depending on which side provides easier access. Hold the ball stud shaft with a 6mm Allen key while removing the nut. Disconnect the link from the mounting point.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
4. 4

   Disconnect tie rod end
   Remove the cotter pin and castle nut from the outer tie rod end where it connects to the steering arm on the knuckle. Use a ball joint separator or pickle fork to separate the tie rod end from the knuckle. Note the orientation and position for reassembly.
   ⚠Do not damage the tie rod end boot during separation. Count the number of exposed threads on the tie rod for approximate alignment reference.
5. 5

   Remove strut-to-knuckle bolts
   Locate the two bolts connecting the strut assembly to the top of the knuckle. These are large bolts that pass through the strut bracket and knuckle. Support the knuckle with one hand or have an assistant hold it, then remove both bolts completely.
   ⚠The knuckle will become loose after the lower ball joint is disconnected. Be prepared to support its weight.
   Torque spec

   Strut Bolts115 Nm (85 lb-ft)
6. 6

   Separate lower ball joint
   Remove the cotter pin from the lower ball joint castle nut. Remove the castle nut from the ball joint stud. Use a ball joint separator or pickle fork to separate the ball joint from the knuckle. Insert the separator between the control arm and knuckle, not between the ball joint boot and knuckle to avoid damage.
   ⚠Avoid damaging the ball joint boot if reusing the control arm. Position separator tool carefully.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
7. 7

   Remove knuckle and hub assembly
   With all connections separated, pull the knuckle assembly outward and off the CV axle shaft. You may need to tap the CV axle from behind with a brass hammer or use a pry bar against the hub to free it from the splines. Remove the knuckle assembly completely from the vehicle.
   ⚠Do not allow the CV axle to hang unsupported or pull outward excessively as this can damage the inner CV joint or pull the axle from the transmission.
8. 8

   Prepare new knuckle assembly
   If installing a new knuckle, transfer any necessary components from the old knuckle such as dust shields or brackets. Clean the CV axle splines with a wire brush and inspect for damage. Apply a thin coat of anti-seize to the axle splines (do not over-apply).
9. 9

   Install knuckle onto CV axle and strut
   Align the new or serviced knuckle onto the CV axle splines and push firmly into place. Swing the knuckle up to align with the strut bracket and insert both strut-to-knuckle bolts. Install nuts on strut bolts but do not fully tighten yet.
10. 10

    Connect lower ball joint
    Align the lower ball joint stud with the hole in the bottom of the knuckle. You may need to use a pry bar to position the control arm or knuckle for alignment. Install the castle nut and tighten to specification. Install a new cotter pin through the castle nut and ball joint stud, bending the ends to secure.
    Torque spec

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

    Connect tie rod end
    Insert the tie rod end stud into the steering arm on the knuckle. Install the castle nut and tighten to specification (approximately 50 Nm if not provided in spec list). Install a new cotter pin and secure by bending the ends.
12. 12

    Torque strut bolts and reconnect sway bar
    Fully torque the two strut-to-knuckle bolts to specification. Reconnect the sway bar end link, holding the ball stud with a 6mm Allen key while tightening the nut to specification.
    Torque spec

    Strut Bolts115 Nm (85 lb-ft)

    Sway Bar Link Nuts55 Nm (41 lb-ft)
13. 13

    Install ABS sensor and brake components
    Insert the ABS wheel speed sensor into its bore in the knuckle and secure with the mounting bolt. Reconnect the ABS electrical connector ensuring it clicks into place. Install the brake rotor onto the hub. Mount the brake caliper over the rotor and install the two caliper mounting bolts, torquing to specification.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
14. 14

    Install axle nut and wheel
    Install the new 32mm axle hub nut onto the CV axle shaft and tighten by hand. Install the wheel and thread lug nuts by hand. Lower vehicle until tire contacts ground but is not fully weighted. Torque lug nuts in a star pattern to specification. With vehicle still partially supported, torque the axle nut to approximately 216 Nm (160 lb-ft) while having an assistant apply the brakes.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
15. 15

    Final torque and stake axle nut
    Fully lower the vehicle to the ground. Using a chisel or punch, stake the axle nut collar into the CV axle groove to prevent loosening. Pump the brake pedal several times until firm before moving vehicle.
    ℹ️The control arm bolts should be torqued with vehicle weight on the suspension. If they were disturbed, perform this torque with vehicle on ground.

Reassembly

1. All fasteners with torque specifications must be tightened to spec using a calibrated torque wrench
2. New cotter pins must be used for all ball joint connections
3. A new axle hub nut must be used - never reuse the old nut
4. Control arm bolts should be torqued with vehicle weight on wheels if they were removed or loosened

Verification

• Verify the axle nut has been properly staked and is secure
• Check that all cotter pins are properly installed and bent
• Pump brake pedal until firm before test driving
• Verify ABS sensor connector is fully seated and secured
• Test drive vehicle at low speed and verify no unusual noises or vibrations
• Schedule a professional wheel alignment as suspension geometry has been disturbed

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