This procedure covers the replacement of damaged or worn wheel studs on the front or rear hub assemblies of a 2019-2024 Toyota RAV4 with the 2.5L I4 engine and FWD configuration.

Warnings

Tools required

Parts

• Wheel stud(s) × 1 — Toyota OEM 90942-02069 or equivalent

Preparation

1. Park vehicle on level ground and engage parking brake
2. Chock the wheels that will remain on the ground
3. Loosen wheel lug nuts 1/4 turn before raising vehicle
4. Raise vehicle with floor jack and secure on jack stands at manufacturer-specified lift points
5. Remove wheel and tire assembly completely

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the brake caliper mounting bolts and secure the caliper to the suspension using wire or a bungee cord without stressing the brake line. Remove the caliper bracket if needed for clearance. Slide the brake rotor off the hub. If rotor is stuck, use gentle taps with a rubber mallet on the rotor face.
2. 2

   Inspect damaged stud location
   Identify which wheel stud(s) need replacement. Check the hub face for any damage or debris. Clean the hub mounting surface with a wire brush if necessary. Note the orientation of the stud - it should be driven out from the front (outer) side of the hub toward the back.
3. 3

   Remove damaged wheel stud
   Using a brass drift punch and ball peen hammer, strike the back of the damaged stud to drive it out through the front of the hub. Position the punch on the stud threads behind the hub flange and strike firmly. The stud will press out of its knurled interference fit. Rotate the hub or reposition as needed for hammer clearance.
   ⚠Wear safety glasses during stud removal. Flying metal fragments can cause injury.
4. 4

   Clean stud mounting hole
   Once the old stud is removed, clean the mounting hole in the hub thoroughly with a wire brush. Remove any rust, debris, or metal shavings. The hole must be clean for the new stud to seat properly. Inspect the hole for damage - if the hole is wallowed out or cracked, the hub requires replacement.
5. 5

   Insert new wheel stud
   Insert the new wheel stud from the back (inner) side of the hub, pushing it through until the knurled shoulder contacts the hub. Ensure the stud is started straight and fully seated in the hole before proceeding to the next step.
6. 6

   Draw stud into hub
   Install a wheel stud installation tool, or use a stack of washers and a lug nut with a large C-clamp or appropriately sized spacer. Thread the lug nut onto the new stud and tighten gradually to draw the stud into the hub until the knurled shoulder is fully seated against the back of the hub flange. You will feel significant resistance as the knurled portion pulls through. Do not use an impact gun for this step.
   ⚠Ensure the stud remains straight during installation. A cocked stud will damage the hub and require hub replacement.
7. 7

   Verify stud installation
   Remove the installation tool or washer stack. Verify the stud shoulder is fully seated flush against the back of the hub with no gap. The stud should not rotate by hand. Check that adequate thread protrudes from the hub face - compare to adjacent studs for reference.
8. 8

   Reinstall brake rotor
   Clean the hub face and rotor mounting surface with a wire brush. Slide the brake rotor back onto the hub, aligning the rotor holes with the remaining wheel studs. The rotor should sit flat against the hub face.
9. 9

   Reinstall brake caliper
   If removed, reinstall the caliper bracket with its mounting bolts torqued to specification. Position the brake caliper over the rotor and install the caliper mounting bolts. Torque caliper bolts per manufacturer specification. Do not torque specifications are not provided in this procedure - consult service manual for caliper bolt torque.
10. 10

    Install wheel and torque lug nuts
    Mount the wheel onto the hub, threading all lug nuts by hand to ensure proper seating. Snug all lug nuts in a star pattern with a wrench. Lower the vehicle until the tire just contacts the ground to prevent wheel rotation. Torque all lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
11. 11

    Lower vehicle and final torque check
    Fully lower the vehicle and remove jack stands. With the vehicle on the ground, perform a final torque check on all lug nuts in a star pattern to ensure proper seating and torque value.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. All components are reassembled during the procedure steps
2. Ensure brake caliper bolts are torqued to manufacturer specification from service manual

Verification

• Verify the new wheel stud is fully seated with no gap behind the hub flange
• Confirm the stud does not rotate by hand once installed
• Check that all lug nuts torque properly to specification on the new stud
• Test drive vehicle at low speed and recheck lug nut torque after 50-100 miles

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