How to Change Lower Control Arms on a 2006 Toyota Highlander EV
If you own a 2006 Toyota Highlander EV and you’ve started to notice clunking noises when driving over bumps, uneven tire wear, or vague steering, your lower control arms might be the culprit. The lower control arms connect the suspension to the vehicle’s frame, keeping your wheels stable and aligned. Over time, the bushings or ball joints in the control arms can wear out, and replacement becomes necessary.
This guide will walk you through the process of changing the lower control arms on a 2006 Highlander EV.
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Tools and Supplies You’ll Need
Jack and jack stands (or a lift if you have access)
Lug wrench
Socket set and ratchet
Breaker bar
Torque wrench
Pry bar
Hammer and punch
Penetrating oil (like PB Blaster)
Replacement lower control arms (make sure they fit the Highlander EV model)
Safety glasses and gloves
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Step 1: Preparation and Safety
1. Park the vehicle on a flat surface, engage the parking brake, and chock the rear wheels.
2. Loosen the front lug nuts while the vehicle is still on the ground.
3. Jack up the front of the vehicle and secure it with jack stands. Never work under a car supported only by a jack.
4. Remove the front wheels.
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Step 2: Locate the Lower Control Arm
The lower control arm is a triangular-shaped piece of suspension that connects to the frame with bushings and to the steering knuckle with a ball joint. On the Highlander EV, there are usually two mounting bolts for the bushings and one ball joint connection.
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Step 3: Remove the Ball Joint
1. Spray penetrating oil on the ball joint nut and let it soak.
2. Use a socket and breaker bar to loosen the castle nut.
3. Once the nut is removed, use a hammer and punch or a ball joint separator to free the ball joint stud from the knuckle. Sometimes a few sharp blows to the side of the knuckle help release it.
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Step 4: Unbolt the Control Arm from the Frame
1. Locate the two main bolts that secure the control arm bushings to the subframe.
2. Spray them with penetrating oil and let them sit—it’s common for these bolts to be seized.
3. Use a breaker bar or impact wrench to remove them. This can take some force, so patience is key.
4. Once both bolts are out, pry the control arm loose from the subframe.
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Step 5: Install the New Control Arm
1. Position the new control arm into the subframe and line up the bushing mounts.
2. Insert the bolts by hand first, then snug them down with a ratchet. Don’t torque them fully yet—you’ll want the suspension loaded (vehicle weight on the wheels) before final tightening.
3. Reconnect the ball joint stud into the steering knuckle and tighten the castle nut. Don’t forget to install the cotter pin for safety.
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Step 6: Reassembly and Torque Specs
1. Reinstall the wheels and lower the vehicle back to the ground.
2. With the vehicle’s weight on the suspension, torque the control arm bolts to manufacturer specs:
Lower control arm bushing bolts: ~129 ft-lbs
Ball joint castle nut: ~94 ft-lbs (always confirm with a repair manual)
3. Double-check that all bolts are tightened properly and that cotter pins are secured.
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Step 7: Alignment
After replacing control arms, your alignment will almost certainly be off. Schedule a professional wheel alignment to avoid uneven tire wear and poor handling.
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Final Thoughts
Changing the lower control arms on a 2006 Toyota Highlander EV is a moderately challenging DIY project. It requires patience, the right tools, and a safe working setup, but it’s absolutely doable for a home mechanic. Not only will it save you a lot on labor costs, but it’s also rewarding to know you’ve restored your vehicle’s suspension and handling with your own hands.
If you’ve been noticing steering looseness or suspension clunks, tackling your control arms might just be the solution.