REAR SUSPENSION: REAR SUSPENSION MEMBER (for HV Model AWD): INSTALLATION; 2024 - 2025 MY RAV4 HV [10/2023

Last Modified: 05-08-2025	6.11:8.1.0	Doc ID: RM100000002P1J5
Model Year Start: 2024	Model: RAV4 HV	Prod Date Range: [10/2023 - ]
Title: REAR SUSPENSION: REAR SUSPENSION MEMBER (for HV Model AWD): INSTALLATION; 2024 - 2025 MY RAV4 HV [10/2023 - ]

INSTALLATION

PROCEDURE

1. INSTALL HOLE PLUG

(a) Install the 6 hole plugs to the rear suspension member sub-assembly.

HINT:

There are 2 different shapes of hole plug.

2. INSTALL DIFFERENTIAL MOUNT CUSHION

(a) Using SST, install a new differential mount cushion.

SST: 09316-12010

SST: 09570-24011

*1	Rear Suspension Member Sub-assembly	-	-
*a	-3° to 3°	*b	3.1 to 4.1 mm (0.1220 to 0.1614 in.)
*c	Protrusion	*d	Turn
*e	Hold	-	-
	Turning Direction		Front of Vehicle
	SST Bolt Position	-	-

NOTICE:

Make sure that the differential mount cushion is aligned within 3° from the center.
Install the differential mount cushion so that the protrusion is positioned as shown in the illustration.
Be sure to use the correct combination of SST.
Before using SST, apply grease to SST bolt.
Temporarily install the differential mount cushion to the rear suspension member sub-assembly in order to prevent it from tilting, and then install SST.
Make sure that SST contacts the entire circumference of the differential mount cushion.
Do not tilt the bolts of SST.

3. INSTALL REAR SUSPENSION MEMBER FRONT BODY MOUNTING CUSHION (for LH Side)

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4. INSTALL REAR SUSPENSION MEMBER FRONT BODY MOUNTING CUSHION (for RH Side)

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5. INSTALL REAR SUSPENSION MEMBER REAR BODY MOUNT CUSHION LH

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6. INSTALL REAR SUSPENSION MEMBER REAR BODY MOUNT CUSHION RH

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7. INSTALL REAR UPPER CONTROL ARM ASSEMBLY LH

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8. INSTALL REAR UPPER CONTROL ARM ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

9. INSTALL REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY

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10. CONNECT WIRE HARNESS

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11. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY

(a) for TMC Made:

(1) Install the 4 rear suspension member cushions to the rear suspension member sub-assembly.

HINT:

When reusing the rear suspension member cushion, make sure to check its identification mark and install it to the correct position.

(b) for TMMC Made:

(1) Install the 2 rear suspension member cushions and 2 upper differential support member stoppers to the rear suspension member sub-assembly.

HINT:

When reusing the rear suspension member cushion and upper differential support member stopper, make sure to check its identification mark and install it to the correct position.

(c) Using an engine lifter and 4 attachments or equivalent tools, support the rear suspension member sub-assembly as shown in the illustration.

CAUTION:

The rear suspension member sub-assembly is a very heavy component. Make sure that it is supported securely.
If the rear suspension member sub-assembly is not securely supported, it may drop, resulting in serious injury.

NOTICE:

Use attachments or equivalent tools to keep the rear suspension member sub-assembly level.
Keep supporting the rear suspension member sub-assembly until the installation has been completed.

*a	Engine Lifter
*b	Attachment
	Attachment and Wooden Block Placement Location

(d) Raise the rear suspension member sub-assembly until there is no clearance between the rear suspension member sub-assembly and vehicle.

(e) Install the rear suspension member sub-assembly with the 2 rear suspension member lower stoppers, rear suspension member lower brace LH and rear suspension member lower brace RH, 2 bolts and 4 nuts.

Torque:

Bolt A :

158 N·m {1611 kgf·cm, 117 ft·lbf}

Nut B :

158 N·m {1611 kgf·cm, 117 ft·lbf}

Nut C :

18 N·m {184 kgf·cm, 13 ft·lbf}

(f) w/ Height Control Sensor:

(1) Engage the 5 clamps to install the wire harness.

(g) w/o Height Control Sensor:

(1) Engage the 4 clamps to install the wire harness.

(h) Pass the connector through the hole to the inside of the vehicle and install the grommet of the wire harness.

(i) w/ Height Control Sensor:

(1) Connect the 2 connectors.

(j) w/o Height Control Sensor:

(1) Connect the connector.

12. INSTALL FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Install the HV floor under wire to the rear traction motor with transaxle assembly with the 2 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

NOTICE:

Make sure that the connector is fully engaged.
Do not damage the terminals, interlock connector or rear traction motor with transaxle assembly during installation.
Do not touch the waterproof seal or terminals of the connector.
Do not allow any foreign matter or water to enter the rear traction motor with transaxle assembly.
Although the connector may feel loose, this is not due to a malfunction.

*a	Waterproof Seal

(b) Engage the clamp.

13. TEMPORARILY INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY LH

(a) Temporarily install the rear No. 1 suspension arm assembly to the rear suspension member sub-assembly with the bolt and nut.

NOTICE:

Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.
Insert the bolt with the threaded end facing the rear of the vehicle.

14. TEMPORARILY INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

15. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY LH

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16. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

17. INSTALL REAR DRIVE SHAFT ASSEMBLY LH

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18. INSTALL REAR DRIVE SHAFT ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

19. INSTALL REAR STABILIZER BAR

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20. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH

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21. INSTALL LUGGAGE HOLD BELT STRIKER ASSEMBLY

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22. INSTALL TETHER ANCHOR BRACKET SET

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23. INSTALL REAR SEAT SIDE GARNISH LH

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24. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH

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25. INSTALL REAR DOOR SCUFF PLATE LH

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26. INSTALL REAR NO. 1 FLOOR MAT SUPPORT SIDE PLATE

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27. INSTALL REAR FLOOR FINISH PLATE

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28. INSTALL REAR NO. 3 FLOOR BOARD

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29. INSTALL REAR DECK FLOOR BOX (w/o Spare Tire)

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30. INSTALL DECK BOARD ASSEMBLY

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31. INSTALL TONNEAU COVER ASSEMBLY (w/ Tonneau Cover)

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32. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH

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33. INSTALL REAR SEAT ASSEMBLY

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34. STABILIZE SUSPENSION

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35. INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY LH

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36. INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

37. INSTALL NO. 1 FLOOR UNDER COVER (w/ NO. 1 FLOOR UNDER COVER)

(a) Install the No. 1 floor under cover to the rear suspension member sub-assembly with the 3 bolts and 3 clips.

Torque:

Bolt :

7.5 N·m {76 kgf·cm, 66 in·lbf}

38. INSTALL SERVICE PLUG GRIP

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39. INSTALL REAR WHEEL

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40. INSPECT AND ADJUST REAR WHEEL ALIGNMENT

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41. PERFORM INITIALIZATION

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