This procedure covers the removal and replacement of a press-in front wheel bearing on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine and FWD configuration, requiring removal of the steering knuckle and hydraulic press work.

Warnings

Tools required

Parts

• Front wheel bearing assembly (press-in type) × 1 — Use OEM specification
• Axle nut (spindle nut) × 1 — 90179-50091 or equivalent
• Cotter pin for axle nut × 1 — 90751-12010 or equivalent
• Outer bearing seal × 1 — Use OEM specification
• Lower ball joint cotter pin × 1 — 90751-10010 or equivalent
• High-temperature bearing grease × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground, apply parking brake, and chock rear wheels
2. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground
3. Remove center cap from wheel and use breaker bar to loosen (but not remove) the 36mm axle nut while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands placed on factory pinch weld points
5. Remove front wheel completely
6. Clean all brake and suspension components with brake cleaner to remove road debris

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the two brake caliper slide pin bolts on the rear of the caliper bracket using a 17mm socket. Lift caliper off rotor and secure it to the strut spring with wire or zip ties - do not let it hang by the brake hose. Remove the caliper bracket mounting bolts (two 19mm bolts) and remove bracket. Pull rotor off hub; if stuck, use two M8 threaded holes to press it off with bolts.
2. 2

   Disconnect ABS wheel speed sensor
   Locate the ABS wheel speed sensor on the back of the steering knuckle. Disconnect the electrical connector by pressing the release tab. Remove the single sensor mounting bolt using a 10mm socket. Carefully extract the sensor from the knuckle bore - it may be corroded in place, so work it back and forth gently. Note the sensor routing for reinstallation.
   Torque spec

   ABS Sensor Bolt11 Nm (8 lb-ft)
3. 3

   Remove axle nut and separate axle from hub
   Remove the previously loosened 36mm axle nut completely and set aside (this is a single-use item). The axle should now be loose in the hub bore. You may need to tap the end of the axle with a dead blow hammer to break the taper fit. Do not remove the axle from the transmission at this time.
4. 4

   Disconnect outer tie rod end
   Remove the 17mm castle nut from the outer tie rod end ball joint stud. Remove the cotter pin first. Use a ball joint separator or pickle fork to separate the tie rod end from the steering knuckle arm. Count and record the number of exposed threads on the tie rod for alignment reference during reassembly.
5. 5

   Disconnect lower ball joint from knuckle
   Remove the cotter pin and 19mm castle nut from the lower ball joint stud. Use a ball joint separator to break the taper between the lower control arm ball joint and the steering knuckle. Support the knuckle assembly as the ball joint separates to prevent the CV axle from dropping out of the transmission.
6. 6

   Separate knuckle from strut assembly
   Locate the two 18mm bolts connecting the steering knuckle to the strut assembly (through the strut bracket). Mark the exact position of the cam bolt if equipped for alignment purposes. Remove both bolts and carefully separate the knuckle from the strut. Pull the CV axle out of the hub bore and set the knuckle assembly on a clean workbench.
7. 7

   Remove hub from knuckle
   With the knuckle on a workbench, remove the four hub mounting bolts from the back of the knuckle using a 14mm socket. These bolts secure the hub to the bearing inner race. The hub should now separate from the knuckle. If stuck, use a soft drift and hammer to tap it out evenly from the rear. Be careful not to damage the ABS reluctor ring on the hub.
   Torque spec

   Hub Bolts102 Nm (75 lb-ft)
8. 8

   Press old bearing out of knuckle
   Inspect the knuckle bore for the bearing retaining snapring on the inboard side. Use snapring pliers to remove it. Place the knuckle on the hydraulic press bed with the outboard side facing up. Use a press adapter that contacts ONLY the outer bearing race (not the inner race or cage). Press the bearing assembly out of the knuckle bore. Remove the outer seal from the outboard side of the knuckle if it did not come out with the bearing.
   ⚠️Ensure press adapters contact only the bearing outer race. Pressing on the inner race or cage can cause the bearing to explode.
9. 9

   Clean and inspect knuckle bore
   Thoroughly clean the knuckle bearing bore with brake cleaner and a wire brush. Remove all rust, corrosion, and old grease. Inspect the bore for scoring, cracks, or damage. Check that the snapring groove is clean and undamaged. The bore should be smooth with no raised edges or burrs.
10. 10

    Install new bearing into knuckle
    Apply a thin film of high-temperature bearing grease to the cleaned knuckle bore. Place the knuckle on the press bed with the inboard side facing up. Position the new bearing assembly squarely in the bore, ensuring it is not cocked. For easier installation, chill the bearing in a freezer for 30 minutes and/or heat the knuckle bore gently with a heat gun. Use a press adapter that contacts ONLY the outer bearing race and press the bearing in until it seats fully against the shoulder in the bore. Install the bearing retaining snapring into its groove. Install the new outer seal into the outboard side using a seal driver.
    ⚠The bearing must be pressed in squarely to avoid cocking and binding. Stop immediately if resistance increases abnormally.
11. 11

    Install hub into new bearing
    Apply a light coat of bearing grease to the bearing inner races and the hub mating surface. Position the hub into the knuckle from the outboard side, ensuring the ABS reluctor ring faces outward. Thread the four hub mounting bolts through from the back of the knuckle and hand-tighten. Torque the four hub bolts evenly in a cross pattern to 102 Nm (75 lb-ft) to properly seat the hub and preload the bearing.
    Torque spec

    Hub Bolts102 Nm (75 lb-ft)
12. 12

    Reinstall knuckle assembly to vehicle
    Guide the CV axle shaft back through the hub bore. Align the knuckle with the strut bracket mounting holes and insert the two strut-to-knuckle bolts. If cam bolts were present, align them to the marks made during disassembly. Hand-tighten bolts initially. Reconnect the lower ball joint to the knuckle and install the castle nut. Torque the lower ball joint nut to specification and install a new cotter pin. Reconnect the outer tie rod end, torque its castle nut to specification, and install a new cotter pin.
13. 13

    Install axle nut and remaining components
    Install the NEW axle nut onto the CV axle shaft and hand-tighten. Insert the ABS wheel speed sensor back into its bore in the knuckle, ensuring the tip is clean and undamaged. Install the ABS sensor mounting bolt and torque to 11 Nm (8 lb-ft). Reconnect the ABS sensor electrical connector. Reinstall the brake caliper bracket and torque its bolts to specification. Install the brake rotor and reinstall the brake caliper, torquing slide pin bolts to specification.
    Torque spec

    ABS Sensor Bolt11 Nm (8 lb-ft)
14. 14

    Torque axle nut and install wheel
    Reinstall the wheel and hand-tighten lug nuts. Lower the vehicle until the tire just touches the ground but most weight is still on the jack stands. This prevents the hub from spinning. Use a torque wrench to tighten the 36mm axle nut to 250 Nm (184 lb-ft). Stake the axle nut collar into the CV axle shaft groove using a punch and hammer, or install a new cotter pin if the design uses one. Torque the wheel lug nuts in a star pattern to 140 Nm (103 lb-ft). Lower the vehicle completely and remove jack stands.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification and new single-use fasteners (axle nut, cotter pins) are installed
2. Verify ABS sensor connector is fully seated and sensor wiring is properly routed away from moving suspension components
3. Check that brake caliper slide pins move freely and brake hose is not twisted or kinked
4. Verify CV axle nut is properly staked or cotter pin is installed to prevent loosening

Verification

• Test drive the vehicle at low speed in a safe area and listen for any grinding, humming, or abnormal noise from the wheel bearing area
• Perform several moderate brake applications to verify proper brake function
• Check for proper ABS operation by verifying the ABS warning light on the dash turns off after starting the vehicle and driving briefly
• Raise the vehicle again and check for excessive play in the wheel bearing by grasping the tire at 12 and 6 o'clock positions and attempting to rock it - there should be no perceptible movement
• Have the vehicle's alignment checked and adjusted as the camber and toe may have changed during disassembly

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