Coil Spring - Front

This procedure covers the removal and replacement of the front coil springs on a 1994-2007 Dodge Ram 2500 with the 5.9L Cummins diesel engine and 4WD, including suspension disassembly and spring compressor use.

Warnings

Tools required

Parts

• Front coil spring (left or right) × 1 — Use OEM specification or equivalent heavy-duty diesel application
• Cotter pin for ball joint × 1 — Use OEM specification
• Shock absorber isolator bushings (if worn) × 1 — Inspect and replace as needed

Preparation

1. Park vehicle on level, solid surface and set parking brake firmly
2. Chock rear wheels securely on both sides
3. Apply penetrating oil to all suspension fasteners to be removed and allow to soak for 15-30 minutes
4. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground
5. Raise front of vehicle with floor jack at frame rail, not axle
6. Install jack stands under frame rails rated for vehicle weight
7. Remove wheel and tire assembly completely
8. Place floor jack under front axle housing near spring seat to support axle weight (do not lift, just support)
9. Inspect spring compressor tool for damage and ensure it is rated for heavy-duty diesel truck springs

Procedure

1. 1

   Disconnect sway bar link
   Locate the front sway bar link connecting the sway bar to the axle bracket. Hold the link shaft with an Allen key to prevent spinning, then remove the upper nut using a 15mm socket. Swing sway bar link out of the way or remove completely if clearance is needed. Inspect link bushings for wear.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
2. 2

   Remove shock absorber lower mounting
   Locate the lower shock absorber mounting bolt at the axle bracket. Support the shock by hand and remove the lower mounting bolt and nut using a 21mm socket. Do not remove upper shock mount yet. Push shock upward and secure it out of the way with safety wire or zip tie to prevent interference.
   Torque spec

   Strut Bolts115 Nm (85 lb-ft)
3. 3

   Disconnect upper ball joint
   Locate the upper ball joint connecting the steering knuckle to the upper control arm. Remove and discard the cotter pin from the ball joint castellated nut. Using an 18mm socket, loosen (but do not fully remove) the ball joint nut until it is flush with the top of the stud. Use a ball joint separator tool to break the taper between the ball joint stud and knuckle. Once separated, remove the nut completely. Support the knuckle/axle assembly as the upper arm will be free to move.
   ⚠Leave ball joint nut threaded on until taper is broken to prevent sudden separation. Support knuckle weight once ball joint is disconnected.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
4. 4

   Support and lower axle assembly
   With floor jack positioned under axle housing near the spring, slowly and carefully lower the jack to relieve tension on the coil spring. Lower the axle approximately 4-6 inches until spring tension is reduced but spring is still captured between upper and lower seats. Monitor brake hoses and ABS wires to ensure they are not over-extended. Stop if any binding or excessive pull is observed.
   ⚠️Lower axle slowly and carefully. Spring is still under compression. Ensure all brake lines and wiring have sufficient slack before lowering.
5. 5

   Install spring compressor
   Install heavy-duty coil spring compressor onto the coil spring according to manufacturer instructions. Position compressor hooks alternately on opposite sides of the spring, ensuring maximum engagement with coil loops. Hooks must fully engage the coils, not just rest on the edge. Install at least 2-3 compressor sets if using manual screw-type compressors. Ensure compressors are centered and evenly distributed around the spring circumference.
   ⚠️Spring compressor hooks must fully engage coil loops. Partial engagement can cause compressor to slip off under load. Use multiple compressor sets for heavy diesel truck springs.
6. 6

   Compress coil spring
   Begin compressing the spring slowly and evenly, alternating between compressor units if using multiple sets. Compress spring approximately 2-3 inches to fully relieve load between upper and lower spring seats. Periodically check that compressor hooks remain fully engaged and centered on coils. Continue until spring can be moved freely by hand between the spring seats.
   ⚠️Compress spring slowly and evenly. Check compressor engagement frequently. Never rush this step. Stop immediately if compressor begins to slip or spring binds.
7. 7

   Remove compressed spring assembly
   With spring fully compressed and unloaded, carefully guide the spring assembly out from between the upper control arm spring seat and lower axle spring seat. The spring may need to be tilted or rotated slightly to clear mounting points. Keep hands clear of potential pinch points. Place compressed spring assembly in a safe area away from work zone.
   ⚠️Spring is still under compression from compressor tool. Handle carefully and keep away from body. Set aside in secure location where it cannot fall or roll.
8. 8

   Inspect spring seats and isolators
   Inspect both upper (control arm) and lower (axle) spring seats for damage, corrosion, or deformation. Wire brush any rust or debris from seating surfaces. Check rubber spring isolators on both seats for cracking, deterioration, or compression damage. Replace isolators if they show wear. Ensure spring seats are clean and smooth before installing new spring.
9. 9

   Compress new spring
   Install spring compressors onto the new coil spring using the same technique as removal. Position compressor hooks alternately and ensure full engagement with coil loops. Compress the new spring to approximately the same compressed length as the removed spring, allowing it to fit between upper and lower spring seats. Ensure spring is compressed evenly and compressors are secure.
   ⚠️New springs may have different rate or height than old springs. Use caution when compressing. Ensure adequate compression to fit between spring seats.
10. 10

    Install new spring assembly
    Carefully position the compressed new spring between the upper control arm spring seat and lower axle spring seat. Ensure spring end coils are properly seated in the isolators and aligned with spring seat grooves or locating features. The spring may have directional orientation - verify top and bottom ends are correctly positioned. Ensure spring is centered on both seats.
11. 11

    Raise axle and release spring compression
    Using the floor jack under the axle housing, slowly raise the axle upward to compress the new spring between the seats. As axle rises, spring will begin to load. Once spring is approximately halfway loaded, begin carefully loosening spring compressor tools evenly and alternately. Continue raising axle and releasing compressor tension slowly until spring is fully seated and compressors can be completely removed. Verify spring is properly seated on both upper and lower seats.
    ⚠️Raise axle and release spring compressor tension slowly and evenly. Monitor spring seating continuously. Stop if spring begins to cock or misalign.
12. 12

    Reconnect upper ball joint
    Continue raising axle with floor jack until upper ball joint stud aligns with hole in steering knuckle. Clean ball joint stud and knuckle taper with wire brush. Insert ball joint stud into knuckle and install castellated nut. Tighten nut to specification using 18mm socket and torque wrench. Install new cotter pin through castle nut and ball joint stud, then bend pin ends to secure.
    ⚠Ball joint taper must be clean and dry for proper seating. Do not use grease on taper surfaces. Ensure cotter pin is properly installed and secured.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
13. 13

    Reinstall shock absorber lower mount
    Remove safety wire or zip tie securing shock absorber. Guide shock absorber lower mount into position on axle bracket. Install lower mounting bolt and nut. Tighten to specification using 21mm socket and torque wrench. Ensure shock is not twisted or binding.
    Torque spec

    Strut Bolts115 Nm (85 lb-ft)
14. 14

    Reconnect sway bar link
    Position sway bar link into mounting bracket on axle. Install link nut and tighten while holding link shaft with Allen key to prevent spinning. Torque nut to specification using 15mm socket and torque wrench.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)
15. 15

    Reinstall wheel and perform final torque
    Install wheel and tire assembly onto hub. Thread lug nuts by hand to prevent cross-threading. Tighten lug nuts in star pattern progressively using 19mm socket. Remove jack stands and carefully lower vehicle to ground. With full vehicle weight on wheels, perform final torque on lug nuts in star pattern to specification. Check that all suspension fasteners are tight.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. If replacing both front springs, repeat entire procedure for opposite side
2. Control arm bolts must be torqued with vehicle weight on suspension - this may require raising vehicle slightly to access bolts, then lowering to load suspension before torquing
3. Test drive vehicle on smooth road at low speed to verify proper operation and listen for any unusual noises
4. Vehicle ride height should be measured and compared to specification - new springs may require settling period of 50-100 miles

Verification

• Verify all fasteners are torqued to specification, particularly ball joint nuts with new cotter pins installed
• Check that coil springs are properly seated in both upper and lower spring seats with no signs of cocking or misalignment
• Bounce front end of vehicle and verify springs compress and rebound smoothly without noise or binding
• Inspect for adequate brake line and ABS wire slack through full suspension travel
• Verify wheel lug nuts are torqued in star pattern after vehicle has been driven 25-50 miles
• Check front end alignment - spring replacement typically affects ride height which may require alignment adjustment
• Monitor vehicle for first 100 miles for any unusual noises, pulling, or ride quality issues

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle