Ball Joint - Upper

This procedure covers removal and replacement of the upper ball joint on the front suspension of a 1994-2007 Dodge Ram 2500 4WD with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Upper ball joint × 1 — Dana 60 upper ball joint press-in type
• Cotter pin × 1 — Use OEM specification
• Ball joint castle nut × 1 — Use OEM specification if reusing is not possible

Preparation

1. Park vehicle on level surface and place wheel chocks behind rear wheels
2. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
3. Raise front of vehicle and support on jack stands at frame rails
4. Remove front wheel on side being serviced
5. Spray ball joint castle nut, control arm bolts, and steering knuckle area with penetrating oil and allow to soak

Procedure

1. 1

   Support the lower control arm
   Position a floor jack under the front axle housing to support the axle weight. Raise jack just enough to support the weight but do not lift the vehicle higher. This keeps the knuckle stable when the upper ball joint is disconnected.
2. 2

   Remove the ABS wheel speed sensor
   If equipped, disconnect the ABS wheel speed sensor connector and remove the sensor mounting bolt. Carefully remove the sensor from the steering knuckle and secure it out of the way to prevent damage during ball joint service.
3. 3

   Remove the upper ball joint cotter pin and castle nut
   Using pliers or a cotter pin puller, straighten and remove the cotter pin from the upper ball joint castle nut. Discard the old cotter pin. Using a socket and breaker bar, remove the castle nut from the ball joint stud. Keep the nut if it is in good condition for temporary installation during reassembly.
4. 4

   Separate the ball joint from the steering knuckle
   Use a ball joint separator (pickle fork or ball joint puller) to separate the upper ball joint stud from the steering knuckle. Position the separator between the knuckle and control arm, being careful not to damage the axle U-joint boot or ABS components. Strike sharply with a hammer or use puller tension to break the taper loose. The knuckle assembly will now be supported only by the lower ball joint and jack.
   ⚠Ensure floor jack is properly supporting the lower control arm before separating the upper ball joint.
5. 5

   Access the upper ball joint mounting area
   Carefully lower the jack supporting the axle to allow the steering knuckle to drop away from the upper ball joint. This provides clearance to access the upper ball joint. The ball joint is pressed into the axle yoke/knuckle bore.
6. 6

   Remove the old upper ball joint
   Using a ball joint press or C-clamp style pressing tool with appropriate adapters, press the old ball joint out of the upper control arm. Position the receiver cup on the appropriate side of the axle yoke and press on the ball joint body. The ball joint will press out of the axle yoke bore. Clean the ball joint bore in the control arm with a wire brush, removing any rust, dirt, or debris.
7. 7

   Install the new upper ball joint
   Position the new ball joint into the control arm bore from the top side. The ball joint stud should point downward. Using the ball joint press with appropriate adapters, press the new ball joint into the control arm until it is fully seated. The ball joint flange should be flush against the top surface of the control arm. Ensure the joint is pressed in straight and fully seated.
   ⚠Press the ball joint in slowly and keep it aligned to prevent cocking or damage to the control arm bore.
8. 8

   Raise the steering knuckle to the ball joint
   Using the floor jack under the axle housing, carefully raise the steering knuckle assembly upward. Guide the upper ball joint stud through the hole in the top of the steering knuckle. Continue raising until the knuckle tapered bore fully engages the ball joint stud taper.
9. 9

   Install and torque the ball joint castle nut
   Thread the castle nut onto the upper ball joint stud by hand. Using a torque wrench and socket, torque the castle nut to the factory-specified value (verify against the FSM for the specific model year/axle). Align the castle nut slots with the cotter pin hole in the ball joint stud. If necessary, tighten the nut slightly (no more than 1/6 turn) to align the slots. Never loosen the nut to align the cotter pin hole. Install a new cotter pin through the castle nut and ball joint stud, then bend the cotter pin ends to secure.
   Torque spec

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

    Reinstall the ABS wheel speed sensor
    If removed, clean the ABS wheel speed sensor tip and mounting hole in the steering knuckle. Apply a thin coat of anti-seize to the sensor body (not the tip). Install the sensor into the knuckle and tighten the mounting bolt. Reconnect the ABS sensor electrical connector.
11. 11

    Reinstall the wheel and lower vehicle
    Mount the wheel onto the hub and thread lug nuts by hand. Lower the vehicle until the tire just touches the ground but the suspension is not fully loaded. Torque the wheel lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. Ensure the new ball joint is fully seated in the control arm before installing the castle nut
2. Always use a new cotter pin - never reuse old cotter pins
3. Verify the ball joint grease boot is not torn or damaged after installation
4. If the ball joint has a grease fitting, pump 2-3 strokes of chassis grease into the joint

Verification

• Start the vehicle and turn the steering wheel lock-to-lock while stationary to verify no binding or unusual noises from the upper ball joint
• Test drive the vehicle at low speed and verify normal steering feel and no clunking noises from the front suspension
• After 50-100 miles of driving, re-check the ball joint castle nut torque and cotter pin installation
• Inspect for any grease leakage from the ball joint boot
• Schedule a front end alignment check as ball joint replacement can affect toe and camber settings

More procedures for this vehicle