Knuckle/Spindle - Front

This procedure covers removal and replacement of the front steering knuckle/spindle assembly on a 4WD Dodge Ram 2500 with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Front steering knuckle/spindle assembly × 1 — Use OEM or quality aftermarket
• Wheel bearing and hub assembly × 1 — Often replaced with knuckle
• Upper ball joint cotter pin × 1 — 3/16 inch diameter
• Lower ball joint cotter pin × 1 — 3/16 inch diameter
• CV axle seal × 1 — If removing axle shaft
• Anti-seize compound × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands under the frame rails
4. Remove front wheel on side being serviced
5. Spray all fasteners with penetrating oil and allow to soak for 15-30 minutes
6. Support lower control arm with floor jack to maintain suspension position

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the brake caliper mounting bolts and hang the caliper from the frame using wire or a bungee cord. Do not let it hang by the brake hose. Remove the brake rotor by pulling it off the hub studs. If stuck, use penetrating oil and light hammer taps on the backside.
2. 2

   Disconnect ABS sensor
   Locate the ABS wheel speed sensor wire connector near the upper control arm or frame rail. Disconnect the electrical connector. Remove the sensor mounting bolt from the knuckle and carefully extract the sensor from its bore. Set aside to prevent damage.
3. 3

   Remove tie rod end
   Remove the cotter pin from the tie rod end castle nut. Loosen but do not fully remove the castle nut. Use a ball joint separator or pickle fork to separate the tie rod end from the knuckle. Once separated, remove the nut and tie rod end completely. Be careful not to damage the tie rod boot.
4. 4

   Disconnect sway bar link
   Locate the sway bar end link where it connects to the front axle. Hold the shaft with an Allen key to prevent spinning and remove the nut. Disconnect the sway bar link from the mounting point.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
5. 5

   Mark and remove strut-to-knuckle bolts
   Using a paint pen or scribe, mark the position of the strut bracket relative to the knuckle to preserve camber alignment. Remove the two strut-to-knuckle pinch bolts. You may need to spread the knuckle pinch slot slightly with a pry bar to release the strut.
   Torque spec

   Strut Bolts115 Nm (85 lb-ft)
6. 6

   Remove hub and bearing assembly
   Remove the hub mounting bolts from the back of the knuckle. There are typically three bolts accessible from behind. If the hub is stuck in the knuckle, use a hub puller or slide hammer with appropriate adapter to extract it. The hub and bearing come out as a complete unit.
   ⚠Do not hammer directly on the hub studs or bearing as this will damage the bearing assembly.
7. 7

   Support and remove CV axle
   Support the CV axle shaft with wire or a bungee cord to prevent it from dropping and damaging the inner CV joint. Carefully pull the outer CV axle stub shaft out of the hub bore. The axle may remain in the differential or can be removed completely if needed.
   ⚠If the CV axle is removed from the differential, front differential fluid will drain out. Have a drain pan ready and plan to replace the fluid.
8. 8

   Separate upper ball joint
   Remove the cotter pin from the upper ball joint castle nut. Loosen the nut but leave it threaded on a few turns to protect the threads. Use a ball joint separator to break the taper between the ball joint stud and the knuckle. Once separated, remove the nut completely.
   ⚠Keep the nut loosely threaded while using the separator to prevent the knuckle from falling or the joint from separating violently.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
9. 9

   Separate lower ball joint
   Remove the cotter pin from the lower ball joint castle nut. Loosen the nut but leave it threaded on a few turns. Use a ball joint separator to break the taper between the ball joint stud and the knuckle. Once separated, remove the nut completely and remove the knuckle from the vehicle.
   Torque spec

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

    Clean and inspect mating surfaces
    Wire brush all mating surfaces on the control arm ball joints, strut bracket, and hub mounting surface of the new knuckle. Inspect ball joint boots for tears or damage. Check ball joint studs for wear or damage to the taper. Replace any worn components before reassembly.
11. 11

    Install new knuckle to ball joints
    Position the new knuckle over the upper and lower ball joint studs. Install both ball joint nuts and tighten to specification. Install new cotter pins through the castle nuts and bend the tabs to secure. Ensure the cotter pins are properly seated and the nuts cannot loosen.
    ℹ️Always use new cotter pins. Never reuse old cotter pins as they may be weakened.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
12. 12

    Install hub and bearing assembly
    Apply a thin layer of anti-seize compound to the hub mounting surface of the knuckle. Position the new hub and bearing assembly into the knuckle bore. Install the three hub mounting bolts from the rear and tighten to specification in a crisscross pattern.
13. 13

    Reinstall CV axle
    Insert the CV axle stub shaft through the hub and bearing assembly. Ensure the splines engage properly. If the inner CV axle was removed from the differential, insert it back into the differential with a new seal installed. Push firmly until the retaining clip seats.
14. 14

    Attach strut to knuckle
    Align the strut bracket with the knuckle using the alignment marks made during disassembly. Install the two strut-to-knuckle pinch bolts and tighten to specification. This maintains the original camber setting.
    Torque spec

    Strut Bolts115 Nm (85 lb-ft)
15. 15

    Reconnect tie rod and sway bar
    Install the tie rod end into the knuckle taper. Install and tighten the castle nut to specification, then install a new cotter pin. Reconnect the sway bar end link, holding the shaft with an Allen key while tightening the nut to specification.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)
16. 16

    Install ABS sensor and brake components
    Clean the ABS sensor bore in the knuckle with a wire brush. Apply a thin coat of anti-seize to the sensor body and install it into the knuckle. Connect the electrical connector. Install the brake rotor and caliper, torquing caliper mounting bolts to specification.
17. 17

    Install wheel and lower vehicle
    Install the wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground. Torque the 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. If front differential fluid was lost, refill with 3.5 quarts of 75W-90 synthetic gear oil to proper level
2. Pump the brake pedal several times to ensure proper brake caliper piston position
3. Check brake fluid level in master cylinder reservoir and top off if needed with DOT 3 brake fluid

Verification

• Test drive the vehicle at low speed and verify no unusual noises from the front suspension
• Check that steering operates smoothly without binding or unusual resistance
• Verify ABS warning light does not illuminate, indicating proper ABS sensor function
• Re-torque wheel lug nuts after 50-100 miles of driving
• Have a professional alignment performed to set proper camber, caster, and toe specifications

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