This procedure covers the removal and replacement of the rear upper control arm on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine.

Warnings

Tools required

Parts

• Rear upper control arm × 1 — 48630-42100 or aftermarket equivalent
• Ball joint nut × 1 — Use OEM specification if damaged

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks in front of front wheels
3. Loosen rear wheel lug nuts while vehicle is on ground
4. Raise rear of vehicle and support on jack stands at manufacturer recommended lift points
5. Remove rear wheel on side being serviced
6. Apply penetrating oil to ball joint nut and control arm bolts if corrosion is present

Procedure

1. 1

   Support the rear knuckle assembly
   Place a floor jack under the rear knuckle assembly near the lower control arm to support the suspension and relieve tension on the upper control arm. Raise jack just enough to slightly compress the suspension into a neutral position.
2. 2

   Remove ball joint nut
   Using a 19mm socket, loosen and remove the ball joint castle nut connecting the upper control arm to the rear knuckle. Remove and discard the cotter pin if equipped. Do not allow the knuckle to drop suddenly.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
3. 3

   Separate ball joint from knuckle
   Use a ball joint separator tool to disconnect the upper control arm ball joint from the rear knuckle. Insert the tool between the control arm and knuckle, then tighten to apply pressure until the joint releases with a pop. Do not strike the knuckle with a hammer as this may damage suspension components.
4. 4

   Remove front control arm mounting bolt
   Locate the front mounting bolt that secures the upper control arm to the chassis. Using a 17mm socket and wrench, remove the bolt completely. Note the orientation of any washers or spacers for reinstallation.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
5. 5

   Remove rear control arm mounting bolt
   Using a 17mm socket and wrench, remove the rear mounting bolt that secures the upper control arm to the chassis. Support the control arm as you remove the final bolt to prevent it from falling.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Remove upper control arm
   Carefully remove the upper control arm from the vehicle. Inspect the mounting points on the chassis for corrosion or damage. Clean mounting surfaces with a wire brush if necessary.
7. 7

   Install new upper control arm
   Position the new upper control arm into place at the chassis mounting points. Insert both mounting bolts but do not tighten yet. Ensure any washers or spacers are installed in the correct orientation matching the original configuration.
8. 8

   Connect ball joint to knuckle
   Align the ball joint stud with the hole in the rear knuckle. You may need to use the floor jack to adjust knuckle height. Thread the ball joint nut onto the stud by hand to start.
9. 9

   Torque ball joint nut
   Using a torque wrench and 19mm socket, torque the ball joint nut to specification. Install a new cotter pin if equipped, ensuring it passes through the castle nut slots and ball joint stud hole.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
10. 10

    Install wheel and lower vehicle
    Reinstall the rear wheel and hand-tighten all lug nuts in a star pattern. Lower the vehicle until the wheels just touch the ground but the suspension is still slightly unloaded. Do not fully lower yet.
11. 11

    Torque control arm mounting bolts
    With the vehicle weight on the wheels but still supported by jack stands, use a torque wrench with 17mm socket to torque both the front and rear control arm mounting bolts to specification. This ensures the bushings are torqued at proper ride height.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
12. 12

    Final wheel installation
    Fully lower the vehicle to the ground and remove jack stands. Torque the wheel lug nuts to specification in a star pattern using a torque wrench and 21mm socket.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Control arm mounting bolts MUST be torqued with vehicle weight on wheels at normal ride height
2. Verify ball joint castle nut is properly secured with cotter pin if equipped
3. Double-check all fasteners are tightened to specification

Verification

• Test drive vehicle and verify no unusual noises or vibrations from rear suspension
• Check for proper wheel alignment - vehicle should track straight
• Perform visual inspection of all connections to ensure ball joint and mounting bolts are secure
• Schedule a professional wheel alignment as upper control arm replacement affects rear camber and toe settings

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