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

Warnings

Tools required

Parts

• Front lower control arm (radius arm) × 1 — Use OEM specification
• Control arm bushing bolts (if damaged) × 2 — Use OEM specification
• Ball joint castle nut (if damaged or cotter pin type) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground
3. Raise front of vehicle and support on jack stands at manufacturer-specified jacking points on the chassis
4. Remove front wheel on side being serviced
5. Spray control arm bolts, ball joint nut, and mounting hardware with penetrating oil and allow to soak 10-15 minutes

Procedure

1. 1

   Support lower control arm
   Position floor jack under the lower control arm near the ball joint to support the suspension weight. Raise jack just enough to slightly compress the suspension and take load off the control arm bushings. This prevents the arm from dropping suddenly when disconnected.
2. 2

   Disconnect sway bar link (if necessary)
   If the sway bar link interferes with control arm removal, hold the ball stud with a 6mm Allen key and remove the lower sway bar link nut using a 14mm wrench. Separate the link from the control arm. Note the orientation of washers and bushings for reassembly.
   ℹ️Some RAV4 configurations may not require sway bar link disconnection depending on clearance.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
3. 3

   Remove ball joint castle nut
   Remove the cotter pin (if equipped) from the ball joint castle nut. Using a 19mm socket, remove the ball joint nut connecting the control arm to the steering knuckle. Do not fully remove the nut initially - leave it threaded on a few turns to protect threads during separation.
   Torque spec

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

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, separate the ball joint stud from the steering knuckle. Position the separator between the control arm and knuckle, then strike or tighten to break the taper fit. Once separated, remove the castle nut completely and lower the control arm away from the knuckle using the floor jack.
   ⚠Ball joint separator can damage the ball joint boot. If reusing the control arm, use a puller-style separator rather than a pickle fork.
5. 5

   Mark control arm position
   Before removing the control arm mounting bolts, use a paint marker or scribe to mark the position of the control arm relative to the subframe or mounting brackets. This helps maintain approximate alignment during installation.
6. 6

   Remove front control arm mounting bolt
   Using a 19mm socket and wrench, remove the front control arm bushing mounting bolt that connects the control arm to the front subframe. Support the control arm with your hand or jack as you remove this bolt. The bolt passes through the control arm bushing.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
7. 7

   Remove rear control arm mounting bolt
   Using a 19mm socket and wrench, remove the rear control arm bushing mounting bolt. With both mounting bolts removed, lower and remove the control arm from the vehicle. You may need to maneuver the arm around the subframe and sway bar for clearance.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
8. 8

   Clean mounting surfaces
   Use a wire brush to clean the control arm mounting points on the subframe, removing any corrosion, dirt, or old thread locker compound. Inspect the mounting bolt holes for damage or elongation. Clean the ball joint taper seat on the steering knuckle.
9. 9

   Install new control arm
   Position the new control arm into place, aligning it with the marks made during removal. Insert both front and rear mounting bolts through the bushings and thread them into the subframe by hand. Do NOT torque these bolts yet - leave them hand-tight only. The control arm should move freely on the bolts.
   ⚠Control arm bolts must remain loose until vehicle weight is on the suspension to prevent bushing bind and premature wear.
10. 10

    Connect ball joint to knuckle
    Raise the control arm using the floor jack to align the ball joint stud with the hole in the steering knuckle. Insert the stud through the knuckle and install the castle nut. Torque the ball joint nut to specification. If equipped with a cotter pin, align the castle slots and install a new cotter pin, bending the ends to secure.
    Torque spec

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

    Reconnect sway bar link
    If the sway bar link was disconnected, reconnect it to the control arm. Install washers and bushings in correct order, thread on the nut, hold the ball stud with a 6mm Allen key, and torque the nut to specification using a 14mm wrench.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
12. 12

    Install wheel and lower vehicle
    Reinstall the wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tires just touch the ground but the full weight is still on the jack stands. This loads the suspension to the proper ride height position.
13. 13

    Torque control arm bolts with weight on suspension
    With the vehicle at normal ride height (tires touching ground, suspension loaded), torque both the front and rear control arm mounting bolts to specification. This is critical - torquing with suspension hanging will twist the bushings and cause premature failure.
    ⚠This is the most critical step. Control arm bushings must be torqued at ride height or they will fail prematurely.
    Torque spec

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

    Final wheel installation
    Fully lower the vehicle to the ground and remove jack stands. Torque wheel lug nuts to specification in a star pattern using a torque wrench.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification, paying special attention that control arm bolts were torqued with vehicle weight on suspension
2. Verify ball joint castle nut cotter pin is properly installed and secured if equipped
3. Check that sway bar link is properly connected and torqued if it was removed
4. Remove all tools and equipment from under vehicle

Verification

• Test drive vehicle at low speed in a safe area and listen for any unusual noises from the front suspension
• Check for any clunking, rattling, or knocking sounds over bumps that might indicate loose fasteners
• Verify steering feels normal with no pulling or wandering
• Schedule a professional wheel alignment within the next few days, as control arm replacement will likely alter alignment angles
• After 50-100 miles, re-check torque on all control arm fasteners and wheel lug nuts

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