This procedure covers replacement of the inner tie rod end on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine, requiring removal of the outer tie rod, locking mechanism, and the inner tie rod from the steering rack.

Warnings

Tools required

Parts

• Inner tie rod end × 1 — Use OEM specification
• Tie rod lock nut × 1 — Reusable if not damaged
• Cotter pin × 1 — Use OEM specification
• Steering rack boot/bellows (if damaged) × 1 — Inspect during service

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands at manufacturer-designated lift points
5. Remove front wheel on side requiring service
6. Spray all tie rod threads and fasteners with penetrating oil if corroded

Procedure

1. 1

   Remove outer tie rod end from knuckle
   Remove the cotter pin from the outer tie rod end castle nut using pliers. Remove the castle nut. Use a tie rod separator or pickle fork to separate the outer tie rod end ball joint from the steering knuckle. Avoid damaging the steering knuckle or ball joint boot during separation.
2. 2

   Mark tie rod position for reference
   Before loosening anything, use a permanent marker or paint pen to mark the position of the outer tie rod end where it threads onto the inner tie rod. Also measure and record the exposed thread length from the tie rod lock nut to the end of the inner tie rod threads. This will help approximate toe setting during reassembly.
3. 3

   Remove tie rod lock nut
   Loosen and remove the lock nut that secures the outer tie rod to the inner tie rod. This nut is located between the outer tie rod end and the steering rack boot. Keep track of the nut position relative to your reference marks.
4. 4

   Remove outer tie rod end
   Thread the outer tie rod end off the inner tie rod by rotating it counterclockwise. Count the number of turns required to remove it and record this number for reassembly reference.
5. 5

   Remove or fold back steering rack boot
   Carefully peel back or remove the steering rack boot/bellows from the inner tie rod end to expose the flat surfaces or hex section of the inner tie rod where it connects to the steering rack. Inspect the boot for tears or damage and replace if necessary.
   ⚠The steering rack boot must seal properly to prevent contamination of the steering rack. Replace if torn or damaged.
6. 6

   Remove inner tie rod end
   Using an inner tie rod removal tool or large adjustable wrench, grip the flat surfaces of the inner tie rod end near the steering rack. Rotate counterclockwise to unthread the inner tie rod from the steering rack. The inner tie rod typically requires 40-60 ft-lbs of force to break loose. If using a wrench on the flats, be careful not to damage the steering rack housing.
   ⚠Do not use excessive force on the steering rack housing. Support the rack if necessary to prevent damage.
7. 7

   Clean threads and inspect steering rack
   Use a wire brush to clean the threads on the steering rack where the inner tie rod attaches. Inspect the threads for damage. Check inside the steering rack boot area for excessive grease loss or contamination that might indicate rack seal failure.
8. 8

   Install new inner tie rod end
   Thread the new inner tie rod end onto the steering rack by hand, rotating clockwise. Apply light thread locker if desired (check manufacturer specifications). Once hand-tight, use the inner tie rod tool to tighten the inner tie rod securely. Torque to manufacturer specification, typically 60-70 ft-lbs, though this specific torque is not provided in the database for this component. Tighten firmly until snug.
9. 9

   Reinstall steering rack boot
   Position the steering rack boot over the inner tie rod, ensuring it seats properly in the grooves on both the rack housing and the inner tie rod body. Verify the boot is not twisted and forms a complete seal. Install boot clamps if equipped.
10. 10

    Install outer tie rod end
    Thread the outer tie rod end onto the new inner tie rod, aligning with your reference marks from disassembly. Use the same number of turns you counted during removal. This should approximate the previous toe setting.
11. 11

    Install lock nut
    Thread the tie rod lock nut onto the inner tie rod against the outer tie rod end, but do not fully tighten yet. Position it approximately where it was marked during disassembly. Final tightening will occur after alignment.
12. 12

    Connect outer tie rod to knuckle
    Insert the outer tie rod end ball stud into the steering knuckle. Install the castle nut and tighten to specification. Align the castle nut slots with the ball stud hole by tightening only (never loosen to align). Install a new cotter pin and bend the ends to secure.
    ⚠Never loosen the castle nut to align cotter pin holes. Only tighten further until alignment is achieved.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
13. 13

    Reinstall wheel
    Install the wheel and thread lug nuts by hand. Lower the vehicle until the tire just contacts the ground. Torque lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. After wheel installation, verify steering moves freely lock-to-lock without binding
2. Test drive vehicle in a safe area at low speed to verify steering response
3. The tie rod lock nut should only be torqued to final specification AFTER professional wheel alignment is completed

Verification

• Verify all fasteners are properly torqued, especially the outer tie rod castle nut and wheel lug nuts
• Check that the cotter pin is properly installed and bent in the castle nut
• Confirm the steering rack boot is properly seated with no tears or gaps
• Schedule immediate wheel alignment at a professional facility - the tie rod lock nut must be torqued to 68 Nm (50 lb-ft) after alignment is set
• After alignment, verify steering wheel is centered when driving straight and vehicle tracks properly

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