This procedure covers the removal and replacement of the rear wheel knuckle/spindle assembly on a 2019-2024 Toyota RAV4 with 2.5L I4 gas engine and front-wheel drive.

Warnings

Tools required

Parts

• Rear wheel knuckle/spindle assembly × 1 — Use OEM specification
• Rear axle hub nut × 1 — 90179-43005 or equivalent
• Cotter pin for ball joint nut × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks in front of front wheels
3. Loosen rear wheel lug nuts while vehicle is on ground, but do not remove
4. Raise rear of vehicle and support securely on jack stands at manufacturer-specified lift points
5. Remove rear wheel completely
6. Spray all fasteners to be removed with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Remove brake drum and disconnect ABS sensor
   Remove the brake drum by pulling it straight off the hub. If stuck, use two 8mm bolts threaded into the drum holes to push it off. Locate the ABS wheel speed sensor wire connector and disconnect it. Remove the mounting bolt securing the ABS sensor to the knuckle and carefully extract the sensor from the knuckle bore. Set aside the sensor to avoid damage.
   Torque spec

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

   Remove rear axle hub nut
   Have an assistant apply the parking brake firmly or use a pry bar to prevent hub rotation. Using a breaker bar and 30mm socket, remove the rear axle hub nut. This nut is torqued very tight and may require significant force. Discard this nut; a new one must be used during reassembly. Note the presence of any washers or spacers.
3. 3

   Disconnect sway bar link
   Locate the rear sway bar link connection to the lower control arm or knuckle area. Insert an Allen key into the ball stud shaft to prevent rotation. Using a wrench on the nut, remove the sway bar link nut. Separate the sway bar link from its mounting point.
   Torque spec

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

   Remove strut-to-knuckle bolts
   Locate the two bolts securing the strut assembly to the rear knuckle. These are located at the top of the knuckle where it connects to the strut. Support the knuckle with one hand or a jack to prevent it from falling. Remove both strut-to-knuckle bolts completely and note their orientation.
   Torque spec

   Strut Bolts115 Nm (85 lb-ft)
5. 5

   Remove lower control arm connection
   Locate the lower control arm to knuckle connection point. Remove the fasteners connecting the lower control arm to the knuckle. Note that these fasteners should be torqued with vehicle weight on wheels during reassembly. Allow the control arm to hang freely.
   ℹ️Do not fully torque control arm bolts until vehicle is lowered and weight is on suspension.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Disconnect upper ball joint
   Locate the upper ball joint connecting the upper control arm to the top of the knuckle. Remove the cotter pin from the castle nut and discard. Loosen the ball joint nut but do not fully remove it yet. Using a ball joint separator or pickle fork, carefully separate the ball joint taper from the knuckle. Once separated, remove the nut completely.
   ⚠Ball joint separators can damage the ball joint boot. Use care and consider replacement if boot is torn.
   Torque spec

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

   Remove knuckle assembly
   With all connections disconnected, carefully maneuver the knuckle assembly off the rear axle shaft. You may need to use a plastic mallet to gently tap the hub from the axle shaft. Pull the knuckle assembly away from the vehicle. Inspect the axle shaft splines for damage or excessive wear.
   ⚠Do not allow the axle shaft to hang unsupported as this may damage the differential seal or axle bearings.
8. 8

   Prepare new knuckle assembly
   Inspect the new knuckle assembly to ensure it matches the old unit. Transfer any necessary components from the old knuckle if not included with replacement (such as dust shields or brackets). Clean the axle shaft splines with a wire brush. Apply a thin coat of anti-seize to the axle splines.
9. 9

   Install new knuckle onto axle
   Carefully align the new knuckle assembly with the axle shaft splines. Slide the knuckle onto the axle shaft, ensuring proper engagement. Maneuver the knuckle into approximate position for reconnection to suspension components.
10. 10

    Reconnect upper ball joint
    Position the knuckle so the upper ball joint stud can be inserted into the knuckle bore. Install the ball joint 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

    Reconnect lower control arm
    Align the lower control arm to knuckle connection point. Install the fasteners hand-tight only at this stage. These will be torqued to final specification after the vehicle is lowered and weight is on the suspension.
    ℹ️Control arm bolts must be torqued with vehicle at normal ride height.
12. 12

    Reconnect strut to knuckle
    Align the knuckle to the strut mounting holes. You may need to use a jack under the lower control arm to raise the knuckle into position. Install both strut-to-knuckle bolts and torque to specification.
    Torque spec

    Strut Bolts115 Nm (85 lb-ft)
13. 13

    Reconnect sway bar link and install ABS sensor
    Reconnect the sway bar link to its mounting point. Hold the ball stud shaft with an Allen key and torque the nut to specification. Install the ABS wheel speed sensor into the knuckle bore, ensuring it is fully seated. Install the sensor mounting bolt and torque to specification. Reconnect the ABS sensor wire connector.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)

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

    Install new rear axle hub nut
    Install any washers or spacers that were present during disassembly. Thread the new rear axle hub nut onto the axle shaft. Have an assistant apply the parking brake or use a pry bar to prevent rotation. Torque the hub nut to manufacturer specification (typically 216 Nm / 159 lb-ft, though not provided in your torque list - consult service manual for exact value).
    ℹ️Hub nut torque specification not provided in database. Consult factory service manual for proper torque value (typically 216 Nm / 159 lb-ft).
15. 15

    Reinstall brake drum and wheel
    Clean the hub surface with a wire brush. Reinstall the brake drum onto the hub. Install the wheel and thread lug nuts hand-tight. Lower the vehicle until the tire just contacts the ground but weight is not fully on the suspension.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. With vehicle lowered to normal ride height (tire on ground but vehicle still supported by jack stands under frame), torque the lower control arm fasteners to specification
2. Fully lower the vehicle and remove jack stands
3. Torque wheel lug nuts to specification in a star pattern
4. Repeat entire procedure for opposite side if necessary
5. Test drive vehicle in a safe area at low speed to verify proper operation before returning to normal service

Verification

• Verify all fasteners are torqued to specification, particularly control arm bolts with vehicle at ride height
• Check that ABS wheel speed sensor is securely mounted and connector is fully engaged
• Verify brake drum rotates freely without binding or excessive play
• Road test vehicle and verify no abnormal noises, vibrations, or handling issues
• Check for ABS warning light illumination; clear any stored codes if necessary
• Perform a wheel alignment check as suspension geometry has been disturbed

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