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

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — 48068-42050 or aftermarket equivalent
• Upper ball joint castle nut × 1 — Use OEM specification if not reusable
• Cotter pin × 1 — Standard cotter pin for ball joint

Preparation

1. Park vehicle on level ground and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands at manufacturer-specified jacking points
4. Remove front wheel on side being serviced
5. Spray all suspension fasteners with penetrating oil and allow to soak for 10-15 minutes if vehicle is from rust-prone area

Procedure

1. 1

   Access upper control arm
   Locate the upper control arm at the top of the steering knuckle. The control arm connects the knuckle to the frame rail with two mounting bolts at the frame end and a ball joint at the knuckle end.
2. 2

   Remove ball joint cotter pin
   Locate the castle nut on the upper ball joint stud where it connects to the steering knuckle. Remove and discard the cotter pin by straightening the ends and pulling it out with pliers.
3. 3

   Loosen ball joint nut
   Using a 19mm socket, loosen the ball joint castle nut but do not remove it completely yet. Leave the nut threaded on 2-3 turns to protect the threads and prevent sudden separation.
4. 4

   Separate ball joint from knuckle
   Position a ball joint separator tool or pickle fork between the upper control arm and the steering knuckle at the ball joint. Strike the tool firmly with a hammer to break the taper seal. Once the joint is loose, remove the castle nut completely and separate the ball joint stud from the knuckle. Support the knuckle assembly to prevent strain on other components.
   ⚠Using a pickle fork will likely damage the ball joint boot. Use a proper ball joint separator if reusing the control arm.
5. 5

   Remove control arm mounting bolts
   Locate the two control arm mounting bolts that secure the control arm to the frame rail. Using a 17mm socket and wrench, remove both bolts completely. Support the control arm as you remove the second bolt to prevent it from falling.
6. 6

   Remove upper control arm
   Carefully maneuver the upper control arm out of the mounting bracket and away from the vehicle. Inspect the mounting area on the frame for corrosion or damage. Clean the mounting surfaces with a wire brush if necessary.
7. 7

   Prepare new control arm
   Compare the new upper control arm to the old one to verify it is the correct part. Check that the ball joint boots are intact and properly seated. If the control arm includes a new ball joint nut, use it instead of the old one.
8. 8

   Install new control arm to frame
   Position the new upper control arm into the frame mounting bracket. Insert both mounting bolts and hand-thread them to ensure proper alignment. Do not fully tighten these bolts yet - they must be torqued with the vehicle weight on the wheels.
9. 9

   Connect ball joint to knuckle
   Position the steering knuckle so the ball joint stud can be inserted into the knuckle hole. Thread the castle nut onto the ball joint stud and tighten to specification using a torque wrench. Ensure the nut is tightened enough that the next castle slot aligns with the cotter pin hole.
   Torque spec

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

    Install new cotter pin
    Insert a new cotter pin through the castle nut and ball joint stud. Bend the ends of the cotter pin in opposite directions to secure it. Ensure the cotter pin cannot back out.
11. 11

    Reinstall wheel and lower vehicle
    Install the wheel and hand-thread all lug nuts. Lower the vehicle until the tire just contacts the ground but the suspension is not yet fully loaded. Torque the wheel lug nuts in a star pattern to specification.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
12. 12

    Final torque control arm bolts
    With the vehicle weight now on the wheels (either fully lowered or with suspension at normal ride height), torque the two upper control arm mounting bolts to specification. This ensures the control arm bushings are set at the correct position and will not bind or wear prematurely.
    ⚠Failure to torque these bolts with vehicle weight on wheels will cause premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Double-check that all fasteners are properly torqued
2. Verify the cotter pin is properly installed and secured
3. Remove jack stands and fully lower vehicle to ground
4. Perform a final torque check on wheel lug nuts after lowering

Verification

• Test drive the vehicle at low speed and verify no unusual noises from the suspension
• Check for proper steering feel and response
• Visually inspect the control arm installation for proper alignment
• Schedule a professional wheel alignment as soon as possible - suspension geometry has been altered

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