This procedure covers the replacement of both inner and outer tie rod ends on a 2019-2024 Toyota RAV4 with the 2.5L I4 gas engine, including proper torque specifications and alignment preparation.

Warnings

Tools required

Parts

• Outer tie rod end (driver side) × 1 — Use OEM specification
• Outer tie rod end (passenger side) × 1 — Use OEM specification
• Inner tie rod end (driver side) × 1 — Use OEM specification
• Inner tie rod end (passenger side) × 1 — Use OEM specification
• Cotter pins (2mm x 30mm) × 4 — Use OEM specification
• Tie rod lock nuts × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
3. Raise front of vehicle and support securely on jack stands at manufacturer designated lift points
4. Remove both front wheels completely
5. Spray tie rod end castle nuts and lock nuts with penetrating oil and allow 10-15 minutes to soak
6. Mark the current tie rod position by counting threads or measuring distance from inner tie rod boot to outer tie rod end for both sides
7. Take photos of current tie rod positions for reference

Procedure

1. 1

   Remove outer tie rod end - driver side
   Use needle-nose pliers to straighten and remove the cotter pin from the outer tie rod castle nut. Remove the castle nut using a 19mm socket. Use a tie rod removal tool or pickle fork to separate the tie rod end from the steering knuckle. Strike the tool firmly with a hammer if needed, but avoid damaging the steering knuckle threads or ball joint boot.
2. 2

   Remove inner tie rod assembly - driver side
   Using an adjustable wrench or locking pliers, hold the inner tie rod to prevent rotation. Loosen the tie rod lock nut with another wrench. Unscrew the outer tie rod end from the inner tie rod by turning counterclockwise, counting the exact number of turns for reinstallation reference. Once outer tie rod is removed, inspect the inner tie rod boot for damage. If replacing inner tie rod, use appropriate inner tie rod tool or wrench to remove it from the steering rack.
3. 3

   Install new inner tie rod - driver side
   Clean the steering rack threads with a wire brush. Thread the new inner tie rod onto the steering rack by hand until it seats. Torque the inner tie rod to the rack according to manufacturer specifications (typically requires specialized crow's foot wrench). Ensure the tie rod boot is properly seated and not twisted.
4. 4

   Install new outer tie rod - driver side
   Thread the new outer tie rod end onto the new inner tie rod the same number of turns counted during removal, or match the measurement/thread count recorded earlier. Do not fully tighten the lock nut yet. Insert the outer tie rod ball stud into the steering knuckle.
5. 5

   Secure outer tie rod to knuckle - driver side
   Install the castle nut onto the tie rod ball stud and torque to specification. The castle nut slots must align with the ball stud cotter pin hole. If necessary, tighten (never loosen) the nut slightly to align the nearest slot with the hole. Insert a new cotter pin and bend the ends to secure.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
6. 6

   Remove outer tie rod end - passenger side
   Use needle-nose pliers to straighten and remove the cotter pin from the outer tie rod castle nut. Remove the castle nut using a 19mm socket. Use a tie rod removal tool or pickle fork to separate the tie rod end from the steering knuckle. Strike the tool firmly with a hammer if needed, but avoid damaging the steering knuckle threads or ball joint boot.
7. 7

   Remove inner tie rod assembly - passenger side
   Using an adjustable wrench or locking pliers, hold the inner tie rod to prevent rotation. Loosen the tie rod lock nut with another wrench. Unscrew the outer tie rod end from the inner tie rod by turning counterclockwise, counting the exact number of turns for reinstallation reference. Once outer tie rod is removed, inspect the inner tie rod boot for damage. If replacing inner tie rod, use appropriate inner tie rod tool or wrench to remove it from the steering rack.
8. 8

   Install new inner tie rod - passenger side
   Clean the steering rack threads with a wire brush. Thread the new inner tie rod onto the steering rack by hand until it seats. Torque the inner tie rod to the rack according to manufacturer specifications (typically requires specialized crow's foot wrench). Ensure the tie rod boot is properly seated and not twisted.
9. 9

   Install new outer tie rod - passenger side
   Thread the new outer tie rod end onto the new inner tie rod the same number of turns counted during removal, or match the measurement/thread count recorded earlier. Do not fully tighten the lock nut yet. Insert the outer tie rod ball stud into the steering knuckle.
10. 10

    Secure outer tie rod to knuckle - passenger side
    Install the castle nut onto the tie rod ball stud and torque to specification. The castle nut slots must align with the ball stud cotter pin hole. If necessary, tighten (never loosen) the nut slightly to align the nearest slot with the hole. Insert a new cotter pin and bend the ends to secure.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
11. 11

    Reinstall wheels and perform initial check
    Reinstall both front wheels and hand-tighten lug nuts in a star pattern. Lower the vehicle until the tires just touch the ground (still supported by jack). Torque wheel 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)
12. 12

    Perform steering check and prepare for alignment
    With vehicle on the ground and engine off, turn the steering wheel lock-to-lock slowly to verify smooth operation and no binding. Check that the steering wheel returns to center. Visually verify both tie rod boots are properly seated with no twists or tears. DO NOT tighten the tie rod lock nuts until after professional alignment is completed.

Reassembly

1. After professional wheel alignment is completed, the alignment technician will torque the tie rod lock nuts to 68 Nm (50 lb-ft)
2. Verify all cotter pins are properly installed and bent
3. Confirm all wheel lug nuts are torqued to 136 Nm (100 lb-ft)
4. Test drive vehicle at low speeds in a safe area to verify steering operation before returning to normal driving

Verification

• Verify steering wheel is centered when driving straight
• Confirm no unusual noises from front suspension during turns
• Check that vehicle tracks straight without pulling to either side
• Verify alignment printout shows all measurements within manufacturer specifications (toe, camber, caster)
• Inspect tie rod boots for proper seating with no damage or twisting
• Confirm all cotter pins are installed and properly secured
• Re-torque wheel lug nuts after 50-100 miles of driving

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