This procedure covers the removal and replacement of the lower control arm (radius arm) bushings on the 2019-2024 Toyota RAV4 2.5L I4 FWD, requiring control arm removal and bushing press work.

Warnings

Tools required

Parts

• Lower control arm front bushing × 1 — Use OEM specification
• Lower control arm rear bushing × 1 — Use OEM specification
• Ball joint castle nut (if damaged) × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands placed on frame rails
4. Remove front wheel on the side being serviced
5. Spray penetrating oil on all control arm bolts and ball joint nut, allow to soak 10-15 minutes
6. Mark alignment position of control arm mounting bolts with paint for reference

Procedure

1. 1

   Disconnect sway bar link
   Locate the sway bar link connection at the lower control arm. Use an Allen key to hold the ball joint shaft while loosening the nut with a wrench. Remove the nut completely and disconnect the sway bar link from the control arm.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
2. 2

   Remove ball joint cotter pin and nut
   Straighten and remove the cotter pin from the ball joint castle nut. Using a 21mm socket, loosen and remove the ball joint nut from the lower ball joint stud. Do not reuse the cotter pin.
   Torque spec

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

   Separate ball joint from knuckle
   Install a ball joint separator tool between the lower control arm and steering knuckle. Apply pressure to separate the ball joint taper from the knuckle. Alternatively, use a pickle fork, though this may damage the ball joint boot. Once separated, support the knuckle with wire to prevent strain on the brake hose and ABS sensor wire.
   ⚠Ball joint will separate suddenly. Ensure proper hand placement to avoid injury.
4. 4

   Remove rear control arm mounting bolt
   Locate the rear control arm mounting bolt that connects the control arm to the subframe. This is the longer bolt at the rear position. Use a 19mm socket and breaker bar to remove the bolt completely. Support the control arm with your hand as the bolt is removed.
   ℹ️Keep track of any washers or spacers on the mounting bolts for proper reassembly.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
5. 5

   Remove front control arm mounting bolt
   Remove the front control arm mounting bolt that connects the control arm to the subframe. Use a 19mm socket and breaker bar. Once both bolts are removed, carefully lower and remove the control arm from the vehicle.
   Torque spec

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

   Inspect control arm and bushings
   Examine the control arm for cracks, bends, or damage. Inspect the old bushings for deterioration, cracking, or separation. Clean the bushing bores in the control arm with a wire brush to remove rust and debris.
   ℹ️If control arm shows damage or deformation, replace the entire arm rather than just bushings.
7. 7

   Press out old bushings
   Place the control arm in a hydraulic press. Using appropriately sized adapters that support the control arm around the bushing bore, press out the front bushing. Repeat the process for the rear bushing. Ensure the control arm is properly supported to prevent bending during pressing operations.
   ⚠Use press adapters that match bushing diameter. Improper adapter size can damage control arm.
8. 8

   Install new front bushing
   Clean the front bushing bore thoroughly. Position the new front bushing in the bore, ensuring proper orientation (note any offset or directional markings). Using the hydraulic press with proper adapters, press the bushing into the control arm until it is fully seated and flush with the control arm surface. Apply even pressure and ensure the bushing enters straight.
   ⚠Bushings must be pressed in straight to avoid damage. Stop and reposition if bushing cocks in bore.
9. 9

   Install new rear bushing
   Clean the rear bushing bore. Position the new rear bushing with correct orientation. Press the bushing into the control arm using the hydraulic press and appropriate adapters until fully seated. Verify both bushings are properly installed and flush with the control arm mounting surfaces.
   ℹ️Some bushings have alignment marks or flats that must align with control arm features.
10. 10

    Reinstall control arm to subframe
    Position the control arm back into the subframe mounting points. Insert the front and rear mounting bolts through the control arm bushings and subframe brackets. Thread the bolts by hand but do NOT torque at this time. The bolts must only be snugged to hold position until vehicle weight is on the suspension.
    ⚠Do not torque control arm bolts until vehicle is at ride height with weight on wheels. Premature torquing will twist and damage new bushings.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
11. 11

    Reconnect ball joint to knuckle
    Guide the lower ball joint stud into the steering knuckle taper. Install the castle nut and tighten to specification. The nut slots must align with the cotter pin hole; if necessary, tighten further (never loosen) to achieve alignment. Install a new cotter pin and bend the ends to secure.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
12. 12

    Reconnect sway bar link
    Connect the sway bar link to the lower control arm. Install the nut and hold the ball joint shaft with an Allen key while torquing the nut to specification.
    Torque spec

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

    Reinstall wheel and lower vehicle
    Install the wheel and thread the lug nuts by hand. Lower the vehicle until the tire just contacts the ground but the suspension is not yet loaded. Torque the lug nuts in a star pattern to specification. Then lower the vehicle completely so the full weight is on the suspension.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
14. 14

    Final torque control arm bolts at ride height
    With the vehicle at normal ride height and weight fully on the suspension, torque both control arm mounting bolts (front and rear) to specification. This is critical for proper bushing life. Rock the vehicle slightly to settle the suspension before torquing.
    ⚠This step is critical. Torquing control arm bolts off ride height will cause immediate bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Verify all fasteners are torqued to specification in the correct sequence
2. Check that ball joint cotter pin is properly installed and secured
3. Ensure no tools or parts were left in the wheel well

Verification

• Test drive vehicle at low speed and verify no clunking or abnormal noises from front suspension
• Verify steering response feels normal with no pulling or vibration
• Schedule wheel alignment immediately as suspension geometry has been disturbed
• After 50-100 miles, re-check control arm bolt torque at ride height to verify proper seating

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