Control Arm Bushing - Front Upper

This procedure replaces the front upper control arm bushings on a 1994-2007 Dodge Ram 2500 4WD with the 5.9L Cummins diesel engine, requiring removal of the upper control arm and either pressing new bushings in or replacing the entire arm assembly.

Warnings

Tools required

Parts

• Front upper control arm bushing kit (both sides) × 2 — Moog K7397 or equivalent
• Cotter pin (upper ball joint) × 2 — 1/8 inch diameter

Preparation

1. Park vehicle on level ground and engage parking brake
2. Chock rear wheels securely
3. Spray all fasteners to be removed with penetrating oil and allow to soak for 15-30 minutes
4. Loosen wheel lug nuts while vehicle is on ground (do not remove)
5. Raise front of vehicle with floor jack at frame and support on jack stands at frame rails behind lower control arms
6. Remove front wheels completely

Procedure

1. 1

   Support the front axle
   Place a floor jack under the front axle differential housing to support the weight of the axle assembly. Raise jack until it just contacts the axle but does not lift the vehicle off the jack stands. This prevents the axle from dropping when the upper control arm is disconnected.
2. 2

   Remove upper ball joint cotter pin
   Locate the upper ball joint where it connects to the steering knuckle. Straighten and remove the cotter pin from the ball joint castle nut using pliers or a punch. Discard the old cotter pin.
3. 3

   Loosen upper ball joint nut
   Using a 21mm socket, loosen the upper ball joint castle nut but do not remove it completely. Leave the nut threaded on 2-3 turns to protect the threads and prevent the knuckle from separating violently.
   ⚠Do not remove the nut completely at this stage to prevent the ball joint taper from releasing suddenly.
4. 4

   Separate the upper ball joint
   Using a ball joint separator tool or pickle fork, break the taper between the upper ball joint stud and the steering knuckle. Strike the separator firmly with a hammer. Once the taper breaks free, remove the castle nut completely and lower the knuckle away from the ball joint stud. Support the knuckle assembly to prevent strain on the brake hose and ABS wiring.
   ⚠Using a pickle fork will likely damage the ball joint boot. Only use if you are replacing the ball joint or control arm assembly.
5. 5

   Remove upper control arm mounting bolts
   Locate the two control arm mounting bolts that attach the upper control arm to the frame brackets. These are accessible from the engine compartment side. Use an 18mm wrench to hold the nut on the backside while using a 21mm socket and breaker bar to remove the front and rear control arm mounting bolts. Note the orientation and position of any alignment shims or cams for reinstallation.
   ℹ️Mark or photograph the position of any alignment shims or eccentric cams before removal to preserve front end alignment settings.
6. 6

   Remove upper control arm
   Once both mounting bolts are removed, carefully extract the upper control arm from the frame brackets. The arm should come out toward the wheel well. Inspect the arm for cracks, bends, or other damage.
7. 7

   Press out old bushings
   Using a hydraulic press and appropriately sized bushing removal adapters, press the old bushings out of the control arm. Support the arm properly on the press bed and apply steady pressure. The bushings should press out of their bores. Clean the bushing bores thoroughly with a wire brush and inspect for damage or distortion.
   ⚠Ensure the control arm is properly supported during pressing operations to prevent arm distortion or personal injury.
8. 8

   Press in new bushings
   Apply a light coat of dish soap or bushing installation lubricant to the outer sleeve of the new bushings. Position the new bushing squarely in the control arm bore and use the hydraulic press with proper adapters to press the bushing in until it is fully seated and flush with the control arm. Ensure the bushing is oriented correctly with any voids or slots positioned as specified by the bushing manufacturer. Repeat for the second bushing.
   ℹ️Do not use petroleum-based lubricants as they can degrade rubber bushings. Dish soap or silicone spray is acceptable.
9. 9

   Install upper control arm to frame
   Position the upper control arm back into the frame mounting brackets with the new bushings installed. Insert the front and rear mounting bolts through the frame brackets and bushings, reinstalling any alignment shims or cams in their original positions. Thread the nuts onto the bolts finger-tight but do not torque yet.
   ⚠Control arm bolts must NOT be torqued until the vehicle weight is on the suspension to prevent bushing bind and premature failure.
10. 10

    Connect upper ball joint to knuckle
    Raise the steering knuckle assembly up to the upper ball joint stud. Insert the ball joint stud through the hole in the knuckle. Install the castle nut and tighten to specification using a 21mm socket and torque wrench. Install a new cotter pin through the castle nut and ball joint stud, bending the ends to secure.
    Torque spec

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

    Reinstall wheels and lower vehicle
    Install the front wheels and thread lug nuts on by hand. Lower the vehicle using the floor jack until the tires contact the ground but the vehicle weight is not fully on the suspension. Torque the lug nuts to specification in a star pattern. Then lower the vehicle completely so full weight is on the wheels.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)
12. 12

    Torque control arm bolts
    With the vehicle weight fully on the suspension and wheels on the ground, torque the upper control arm mounting bolts to specification. Use a 21mm socket and torque wrench on the bolt head while holding the nut with an 18mm wrench. Torque both front and rear bolts. This step is critical to bushing longevity.
    ⚠Control arm bolts MUST be torqued with vehicle weight on the suspension. Failure to do this will cause premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
13. 13

    Final inspection
    Remove jack stands and lower vehicle completely. Bounce the front end several times to settle the suspension. Re-check all fastener torques. Verify the cotter pin is properly installed and secure. Check for any unusual noises or binding in the suspension.

Reassembly

1. Alignment shims and eccentric cams must be reinstalled in their original positions to minimize alignment changes
2. Always use a new cotter pin for the ball joint castle nut - never reuse old cotter pins
3. Control arm mounting bolts must be torqued with full vehicle weight on the suspension

Verification

• Verify upper ball joint castle nut is torqued to specification and cotter pin is properly installed
• Verify all control arm mounting bolts are torqued to specification with vehicle weight on suspension
• Test drive vehicle at low speed and verify no clunking, popping, or unusual noises from front suspension
• Have front end alignment checked and adjusted as needed since control arm removal may affect alignment settings
• Inspect for any fluid leaks around disturbed brake lines or ABS sensors

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