This procedure covers the removal and replacement of the rear lower control arm on a 2019-2024 Toyota RAV4 2.5L I4 FWD, including disconnection of the ball joint and control arm mounting bolts.

Warnings

Tools required

Parts

• Rear lower control arm assembly × 1 — Use OEM specification
• Ball joint castle nut × 1 — Replace if damaged
• Cotter pin × 1 — Always replace

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock front wheels securely
3. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
4. Raise rear of vehicle with floor jack at manufacturer-specified jacking point
5. Support vehicle on jack stands placed at frame rails, ensuring stability
6. Remove rear wheel on side being serviced
7. Spray penetrating oil on ball joint nut and control arm bolts if corrosion is present

Procedure

1. 1

   Support the rear knuckle assembly
   Position a floor jack under the rear knuckle/spindle assembly to support it and maintain suspension geometry during disassembly. Raise jack just enough to slightly compress the suspension and take load off the control arm.
2. 2

   Remove ball joint cotter pin
   Locate the ball joint where the lower control arm connects to the rear knuckle. Straighten and remove the cotter pin from the castle nut. Discard the cotter pin as it must be replaced.
3. 3

   Loosen ball joint castle nut
   Using a 17mm socket, loosen the ball joint castle nut but do not remove it completely yet. Leave it threaded on a few turns to prevent the ball joint from separating violently when you use the separator tool.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
4. 4

   Separate ball joint from knuckle
   Install a ball joint separator tool between the control arm and knuckle according to the tool manufacturer's instructions. Apply pressure to separate the ball joint taper from the knuckle bore. Once the taper breaks free, remove the castle nut completely and lower the control arm away from the knuckle.
   ⚠Ball joint may separate suddenly. Keep hands and face clear of the separation point.
5. 5

   Remove front control arm mounting bolt
   Locate the front mounting bolt that secures the control arm to the rear subframe/crossmember. Using a 19mm socket and wrench, remove the bolt and washer. Note the orientation of any washers or spacers for reassembly.
6. 6

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt that secures the control arm to the rear suspension member. Using a 19mm socket and wrench, remove the bolt and washer. Support the control arm as you remove this final fastener.
7. 7

   Remove lower control arm
   With both mounting bolts removed, carefully maneuver the lower control arm out of the vehicle. You may need to rotate or angle it to clear surrounding components. Inspect the mounting points on the subframe for damage or excessive rust.
8. 8

   Prepare new control arm
   Compare the new control arm to the old one to verify correct part. Check that the ball joint boots are intact and the bushings are properly installed. Clean the mounting surfaces on the subframe with a wire brush to ensure proper fitment and bolt torque.
9. 9

   Install new control arm
   Position the new lower control arm into the mounting location, aligning the front and rear bushing bores with the mounting holes on the subframe. Insert both mounting bolts with washers finger-tight only. Do NOT torque these bolts yet.
10. 10

    Connect ball joint to knuckle
    Raise the floor jack under the knuckle to align the ball joint stud with the hole in the knuckle. You may need to use a pry bar to align the components. Insert the ball joint stud into the knuckle and thread the new castle nut onto the stud. Torque the castle nut to specification.
    Torque spec

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

    Install new cotter pin
    Align the castle nut slots with the cotter pin hole in the ball joint stud. If the slots do not align, tighten the nut slightly (never loosen) until alignment is achieved. Insert a new cotter pin and bend the legs to secure.
12. 12

    Reinstall wheel and lower vehicle
    Reinstall the rear wheel and hand-tighten the lug nuts in a star pattern. Remove the floor jack from under the knuckle. Lower the vehicle until the suspension is at normal ride height with full vehicle weight on the wheels, but keep the jack stands in place for safety.
13. 13

    Torque control arm mounting bolts at ride height
    With the vehicle weight on the suspension at normal ride height, torque the front and rear control arm mounting bolts to specification in the order: front bolt first, then rear bolt. This ensures the bushings are not preloaded in a twisted position.
    ⚠️Control arm bolts MUST be torqued at ride height. Torquing them while suspended will cause premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
14. 14

    Final torque wheel lug nuts
    Fully raise the vehicle, remove jack stands, and lower completely to the ground. Torque the wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Always use a new cotter pin for the ball joint castle nut
2. Ensure control arm mounting bolts are torqued with vehicle weight on suspension at normal ride height
3. Double-check all fasteners are properly torqued before test driving
4. Verify ball joint castle nut cotter pin is properly installed and secured

Verification

• Test drive vehicle at low speed and verify no clunking or rattling noises from rear suspension
• Perform a steering check to ensure no pulling or abnormal handling characteristics
• Visually inspect the ball joint cotter pin and all fasteners after test drive
• Schedule a four-wheel alignment as suspension geometry has been altered

More procedures for this vehicle