This procedure covers the removal and replacement of the outer tie rod end on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine, requiring post-repair wheel alignment.

Warnings

Tools required

Parts

• Outer tie rod end × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts on affected side while vehicle is on ground (do not remove)
4. Raise front of vehicle with floor jack at designated jacking point
5. Secure vehicle on jack stand at proper support point
6. Remove wheel completely and set aside

Procedure

1. 1

   Locate and measure tie rod position
   Locate the outer tie rod end at the steering knuckle. Before removing, measure the exposed thread length from the inner tie rod to the outer tie rod end lock nut, or mark the position with a paint pen. This measurement ensures approximate toe alignment for safe driving to the alignment shop. Count and record the number of exposed threads visible.
2. 2

   Remove cotter pin and loosen castle nut
   Straighten and remove the cotter pin from the tie rod end castle nut using pliers or a cotter pin removal tool. Discard the old cotter pin. Using a 19mm socket, loosen the castle nut but do not remove it completely yet - leave it threaded on a few turns to protect the threads during separation.
3. 3

   Separate tie rod end from steering knuckle
   Use a tie rod end separator tool or pickle fork to break the taper between the tie rod end ball stud and the steering knuckle. Position the separator tool between the knuckle and tie rod end and strike sharply with a hammer, or use a screw-type separator. Once the taper breaks free, remove the castle nut completely and remove the tie rod end from the knuckle.
   ⚠Using a pickle fork will damage the tie rod end boot. Only use this method if replacing the tie rod end.
4. 4

   Loosen tie rod lock nut
   Using a 17mm wrench, loosen the lock nut that secures the outer tie rod end to the inner tie rod. This lock nut is located on the threaded portion of the inner tie rod, against the outer tie rod end body. Loosen it completely but leave it threaded on the inner tie rod.
5. 5

   Remove outer tie rod end
   While holding the inner tie rod stationary to prevent the steering rack boot from twisting, unthread the outer tie rod end by turning it counterclockwise. Count the number of full rotations required to remove it, which will help during installation. Remove the lock nut from the inner tie rod threads. Clean the threads on the inner tie rod with a wire brush and inspect for damage.
6. 6

   Install new outer tie rod end
   Thread the lock nut onto the inner tie rod first, then thread the new outer tie rod end onto the inner tie rod. Turn it clockwise the same number of rotations counted during removal, or until the measurement matches your initial recording. This provides an approximate starting point for alignment. Do not tighten the lock nut yet.
7. 7

   Install tie rod end into steering knuckle
   Insert the tie rod end ball stud into the steering knuckle taper. Ensure the stud seats fully into the knuckle. Install the castle nut and tighten to specification. The castle nut slots must align with the ball stud cotter pin hole.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
8. 8

   Install new cotter pin
   Insert a new cotter pin through the castle nut and ball stud hole. If the castle nut slots do not align with the hole, tighten the nut further (never loosen) until the next slot aligns. Bend the cotter pin ends to secure it - one end should wrap around the nut and the other should be bent back over the top.
   ⚠Never loosen the castle nut to align the cotter pin hole. Only tighten further to the next slot alignment.
9. 9

   Temporarily secure lock nut
   Hand-tighten the tie rod lock nut against the outer tie rod end body, but do not torque it to specification yet. This will be final-torqued after the wheel alignment is performed. This prevents the tie rod from threading in or out during transport to the alignment shop.
   ℹ️The tie rod lock nut will be torqued to final specification after professional wheel alignment is completed.
10. 10

    Reinstall wheel
    Place the wheel back onto the hub and hand-thread all lug nuts. Lower the vehicle until the tire just contacts the ground to prevent wheel rotation. Torque the lug nuts in a star pattern to specification.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
11. 11

    Lower vehicle and perform final check
    Remove the jack stand and lower the vehicle completely to the ground. Perform a final visual inspection of the tie rod end installation, ensuring the castle nut is secure and the cotter pin is properly bent. Check that the steering wheel turns freely without binding.

Reassembly

1. After professional wheel alignment is performed, ensure the alignment technician torques the tie rod lock nut to 68.0 Nm (50.0 lb-ft)
2. Request a printed copy of the alignment specifications showing toe, camber, and caster readings
3. Verify steering wheel is centered when driving straight after alignment

Verification

• Test drive vehicle at low speeds in a safe area, checking for smooth steering operation without pulling
• Listen for any unusual noises from the front suspension during turns
• Verify no play exists in the tie rod end by having an assistant turn the steering wheel slightly while you observe the tie rod connection at the knuckle
• Schedule wheel alignment immediately - vehicle should not be driven at highway speeds until aligned
• After alignment, verify the tie rod lock nut has been torqued to specification

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