This procedure covers the removal and replacement of the front upper control arm on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine, including ball joint separation and proper torque sequencing.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification
• Ball joint nut (if damaged) × 1 — Use OEM specification
• Control arm bolts (if corroded) × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground
4. Raise front of vehicle with floor jack at designated lift points
5. Support vehicle securely on jack stands under frame rails
6. Remove front wheel completely

Procedure

1. 1

   Inspect and document alignment position
   Before disassembly, inspect the control arm for damage and wear. If possible, mark or measure the position of adjustment cam bolts or eccentric washers for approximate alignment reference during reassembly. Note that professional alignment is still required after this repair.
2. 2

   Remove ball joint castle nut
   Locate the upper control arm ball joint where it connects to the steering knuckle. Remove the cotter pin if present. Using a 17mm socket, loosen and remove the ball joint castle nut. Do not reuse the cotter pin.
3. 3

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, carefully separate the upper ball joint taper from the steering knuckle. Apply penetrating oil if needed. Strike the tool firmly but avoid damaging the ball joint boot if reusing the control arm. The joint will release with a sudden pop.
   ⚠Tool may slip when joint releases. Maintain secure footing and keep hands clear.
4. 4

   Support the knuckle assembly
   Once the ball joint is separated, the knuckle and hub assembly will hang on the lower control arm and strut. Support the knuckle with a bungee cord or wire tied to the strut spring to prevent strain on the brake hose and ABS sensor wire. Do not let it hang freely.
5. 5

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt that secures the control arm to the frame/subframe. This is typically a 14mm bolt. Using a wrench and socket, remove this bolt completely. The bolt may pass through bushings with washers or sleeves - note their positions for reassembly.
6. 6

   Remove front control arm mounting bolt
   Locate and remove the front mounting bolt securing the control arm to the frame/subframe. This bolt may have an eccentric washer or cam adjuster for alignment purposes. Mark the position of any adjustment features before removal. Remove the bolt completely and support the control arm as you extract it.
7. 7

   Remove upper control arm
   With both mounting bolts removed, carefully extract the upper control arm from the vehicle. Maneuver it out of the wheel well, being careful not to damage brake lines, ABS wiring, or other components. Inspect the removed arm for damage, cracks, or worn bushings to confirm replacement necessity.
8. 8

   Prepare mounting surfaces
   Clean the mounting bolt holes in the frame/subframe using a wire brush. Remove any corrosion, dirt, or debris. Inspect the mounting points for damage or elongated holes. Clean the ball joint taper seat on the steering knuckle. Apply a thin coat of anti-seize to bolt threads if in a corrosive environment.
9. 9

   Install new upper control arm
   Position the new upper control arm into the mounting location. Align the bushings with the frame mounting points. Insert both front and rear mounting bolts through the control arm bushings and frame brackets, but do not tighten yet. Thread the bolts in by hand to hold the arm in position. If equipped with cam adjusters, set them to the previously marked positions.
10. 10

    Connect ball joint to knuckle
    Remove the temporary support from the knuckle. Guide the upper control arm ball joint stud into the taper hole in the top of the steering knuckle. Ensure the taper is seated properly. Install the new or cleaned castle nut onto the ball joint stud and thread it down by hand.
    Torque spec

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

    Torque ball joint nut
    Using a torque wrench and 17mm socket, tighten the ball joint castle nut to 88 Nm (65 lb-ft). After reaching torque, advance the nut if necessary to align the next castle slot with the cotter pin hole in the stud. Never loosen the nut to align. Install a new cotter pin and bend the ends to secure.
    Torque spec

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

    Prepare for final torque of control arm bolts
    Reinstall the wheel and thread the lug nuts by hand. Lower the vehicle until the tires just touch the ground but the jack stands are still supporting most of the weight. This preloads the suspension to the correct position for torquing the control arm mounting bolts.
    ⚠Control arm bolts must be torqued with vehicle weight on suspension to prevent bushing bind and premature wear.
13. 13

    Torque control arm mounting bolts
    With the vehicle weight partially on the wheels, torque both the front and rear upper control arm mounting bolts to 165 Nm (122 lb-ft) using a 14mm socket and torque wrench. Torque both bolts in this loaded condition to ensure proper bushing alignment.
    Torque spec

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

    Final wheel installation
    Raise the vehicle slightly to remove jack stands. Carefully lower the vehicle completely to the ground. Using a torque wrench and 19mm socket, torque the wheel lug nuts to 136 Nm (100 lb-ft) in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification in the correct sequence
2. Verify the cotter pin is properly installed and secured in the ball joint nut
3. Check that no brake lines, ABS wires, or other components are pinched or strained
4. Confirm wheel is properly seated on hub before final lug nut torque

Verification

• Bounce the front end of the vehicle several times and verify no unusual noises from the control arm area
• Turn the steering wheel lock-to-lock while stationary and listen for binding or noise
• Perform a visual inspection to confirm all bolts are tight and properly installed
• Test drive at low speed in a safe area to verify normal handling and no noise
• Schedule a professional front-end alignment as soon as possible - alignment will be out of specification after this repair

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