Control Arm Bushing - Front Lower

Remove and replace the front lower control arm bushings on a 1994-2007 Dodge Ram 2500 4WD with 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Front lower control arm bushing kit (left and right) × 1 — Moog K7397 or equivalent
• Ball joint cotter pins × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support on jack stands at frame rails
5. Remove both front wheels
6. Spray ball joint nuts and control arm pivot bolts with penetrating oil

Procedure

1. 1

   Support lower control arm
   Place a floor jack under the lower control arm near the ball joint to support the weight of the suspension. Raise jack slightly to compress suspension and relieve tension on components.
2. 2

   Disconnect sway bar link
   Locate the sway bar link connection to the lower control arm. Use the appropriate wrench to hold the link stud and remove the retaining nut with the correct socket size per the hardware installed. Separate the link from the control arm.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
3. 3

   Remove ball joint cotter pin and nut
   Remove the cotter pin from the lower ball joint castle nut using cotter pin pliers. Remove the castle nut with the correct socket size for this vehicle's ball joint nut. Do not allow the ball joint stud to spin while removing the nut.
   ⚠Keep jack supporting control arm to prevent sudden drop when ball joint separates.
   Torque spec

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

   Separate ball joint from knuckle
   Use a ball joint separator or pickle fork to separate the lower ball joint from the steering knuckle. Strike the separator firmly with a hammer if needed. Once separated, lower the jack slightly to provide clearance for control arm removal.
5. 5

   Remove control arm pivot bolts
   Locate the front and rear control arm pivot bolts that attach the control arm to the frame brackets. Use the correct large socket and breaker bar to remove both bolts. The bolts pass through the control arm bushings. Note the orientation of any washers or spacers.
   ℹ️These bolts are typically very tight and may require significant force to break loose.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Remove control arm
   Pull the control arm away from the frame brackets and maneuver it out from under the vehicle. Inspect the mounting points on the frame for damage, rust, or excessive wear.
7. 7

   Press out old bushings
   Using a hydraulic press or control arm bushing press tool, press out the old bushings from both ends of the control arm. Note the orientation of the bushings and any sleeves inside them. Clean the bushing bores thoroughly with a wire brush to remove rust and debris.
   ⚠Ensure bushing press tool is properly aligned to prevent damage to control arm bore.
8. 8

   Install new bushings
   Apply a light coating of rubber-safe bushing lubricant to the outside of the new bushings. Using the press tool, install the new bushings into the control arm, ensuring they are oriented correctly and fully seated. The bushings should be pressed in until flush with the control arm bore or until they bottom out against the internal stop.
9. 9

   Reinstall control arm
   Position the control arm back into the frame brackets. Insert the front and rear pivot bolts through the frame brackets and bushings, but do NOT torque them yet. Thread nuts onto the bolts finger-tight only.
   ⚠Bushings must be torqued at ride height with vehicle weight on suspension to prevent binding and premature failure.
10. 10

    Reconnect ball joint to knuckle
    Raise the floor jack to lift the control arm and align the ball joint stud with the hole in the steering knuckle. Insert the stud through the knuckle and install the castle nut. Torque the nut to specification and install a new cotter pin through the castle nut and stud.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
11. 11

    Reconnect sway bar link
    Align the sway bar link with the control arm mounting point. Install the retaining nut and torque to specification while holding the link stud with a wrench.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)
12. 12

    Reinstall wheels
    Install both front wheels and thread lug nuts on by hand. Lower vehicle completely so full weight is on the suspension at normal ride height.
13. 13

    Torque control arm bolts at ride height
    With the vehicle at normal ride height on the ground, crawl under and torque both control arm pivot bolts to specification. This is critical for proper bushing life. Then torque wheel lug nuts in a star pattern.
    ⚠Failure to torque control arm bolts at ride height will cause premature bushing failure and binding.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. Repeat all steps for the opposite side if replacing both control arm bushings
2. Verify all fasteners are tightened to specification
3. Check that cotter pins are properly installed and bent

Verification

• Test drive vehicle at low speed and verify no clunking or unusual noises from front suspension
• Check for proper steering response and no pulling to either side
• After 50-100 miles, recheck control arm bolt torque at ride height
• Schedule front end alignment as control arm removal will affect toe and camber settings

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