This procedure covers the removal and replacement of the front lower control arm on a 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine and front-wheel drive.

Warnings

Tools required

Parts

• Front lower control arm × 1 — 48068-0R040 or 48069-0R040 (driver/passenger)
• Ball joint castle nut × 1 — Use OEM specification
• Cotter pin × 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 the ground (do not remove)
3. Raise front of vehicle and support securely on jack stands at the manufacturer-specified jacking points on the front subframe
4. Remove the front wheel on the side being serviced
5. Spray control arm bolts and ball joint nut with penetrating lubricant

Procedure

1. 1

   Support the lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the weight of the suspension components. Raise jack just enough to make light contact - do not lift the vehicle.
2. 2

   Disconnect the ball joint from the knuckle
   Remove the cotter pin from the ball joint castle nut and discard. Using a 19mm socket, remove the ball joint nut. Use a ball joint separator tool to press the ball joint taper out of the steering knuckle. If using a pickle fork, note that it may damage the ball joint boot.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
3. 3

   Remove the front control arm mounting bolt
   Locate the front control arm mounting bolt that connects to the front subframe. This bolt passes through the front bushing of the control arm. Using a 17mm socket and wrench, remove the bolt and nut. Note the orientation of any washers or spacers.
   ⚠Support the control arm with the floor jack to prevent it from dropping suddenly when the bolts are removed.
   Torque spec

   Control Arm Bolts129 Nm (95 lb-ft)
4. 4

   Remove the rear control arm mounting bolt
   Locate the rear control arm mounting bolt that connects to the rear of the control arm at the subframe. Using a 17mm socket and wrench, remove this bolt and nut. Note the orientation of any washers or spacers.
   Torque spec

   Control Arm Bolts129 Nm (95 lb-ft)
5. 5

   Remove the lower control arm
   Lower the floor jack slowly to relieve tension on the control arm. Maneuver the control arm out of the mounting points and away from the vehicle. You may need to angle it to clear the subframe and steering knuckle.
6. 6

   Clean mounting surfaces
   Use a wire brush to clean the mounting bolt holes in the subframe and the ball joint taper seat in the steering knuckle. Remove any rust, dirt, or debris that could prevent proper seating of the new control arm.
7. 7

   Install the new lower control arm
   Position the new control arm into place, aligning the bushings with the mounting holes in the subframe. Insert the front and rear mounting bolts through the bushings and thread the nuts on finger-tight. Do not torque at this time. Insert the ball joint stud into the steering knuckle.
8. 8

   Install and torque the ball joint nut
   Thread the new castle nut onto the ball joint stud. Torque to specification using a 19mm socket. Align the castle nut slots with the hole in the ball joint stud. If necessary, tighten the nut further (never loosen) to align the slots. Install a new cotter pin and bend the ends to secure.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
9. 9

   Set the vehicle to ride height
   Remove the jack stands and lower the vehicle so the suspension is at normal ride height. You can use blocks or alignment stands under the tires to support the vehicle at the correct height while allowing access underneath. The suspension must be at ride height with the vehicle weight on the wheels before torquing the control arm bolts.
   ⚠This step is critical. Torquing bushings when the suspension is at full droop will preload the bushings incorrectly and cause premature failure.
10. 10

    Torque the rear control arm bolt
    With the vehicle at ride height, torque the rear control arm mounting bolt to specification using a 17mm socket and torque wrench. Hold the nut with a wrench while torquing the bolt head.
    Torque spec

    Control Arm Bolts129 Nm (95 lb-ft)
11. 11

    Torque the front control arm bolt
    With the vehicle at ride height, torque the front control arm mounting bolt to specification using a 17mm socket and torque wrench. Hold the nut with a wrench while torquing the bolt head. Note that this bolt has a higher torque specification than the rear bolt.
    Torque spec

    Control Arm Bolts129 Nm (95 lb-ft)
12. 12

    Reinstall the wheel
    Raise the vehicle enough to remove the alignment stands or blocks. Reinstall the wheel and thread the lug nuts on by hand. Lower the vehicle to the ground. Torque the lug nuts to specification in a star pattern using a 19mm socket and torque wrench.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification
2. Verify the ball joint cotter pin is properly installed and bent
3. Double-check that the control arm bolts were torqued at ride height, not at full droop

Verification

• Test drive the vehicle at low speed and verify no unusual noises or vibrations from the front suspension
• Check that steering feels normal with no binding or unusual feedback
• Schedule a professional front-end alignment as soon as possible - suspension geometry has changed with the new control arm
• After 50-100 miles, re-check the torque on all fasteners installed during this procedure

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