Leaf Spring

This procedure covers the removal and replacement of the rear leaf spring on a 1994-2007 Dodge Ram 2500 4WD with 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Rear leaf spring assembly × 1 — OEM or aftermarket replacement spring pack
• Leaf spring shackle bushings × 4 — Use OEM specification
• Leaf spring eye bushings × 2 — Use OEM specification
• U-bolt kit with nuts and washers × 1 — Use OEM specification
• Leaf spring shackle plates × 2 — Use OEM specification if damaged

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks in front of both front wheels
3. Loosen wheel lug nuts on the rear wheel for the side being serviced while vehicle is on ground
4. Apply penetrating oil to all leaf spring mounting bolts, U-bolt nuts, and shackle bolts
5. Raise rear of vehicle using floor jack at differential or frame rail
6. Install jack stands under frame rails on both sides for stability
7. Remove rear wheel completely

Procedure

1. 1

   Support the rear axle
   Position a floor jack under the axle tube near the leaf spring being replaced. Raise jack just enough to slightly compress the leaf spring and support the axle weight. This prevents the axle from dropping when the U-bolts are removed.
2. 2

   Remove shock absorber lower mount
   Locate the lower shock absorber mounting bolt. Remove the nut and bolt securing the shock to the axle mount. Push shock absorber up and out of the way.
3. 3

   Remove U-bolts
   Using the correct socket for the U-bolt nuts (verify size against the actual hardware), remove the four nuts securing the two U-bolts that clamp the leaf spring to the axle housing. Remove the U-bolts, backing plate, and any spacer blocks between the spring and axle. Keep hardware organized for reassembly.
4. 4

   Lower axle slightly
   Carefully lower the floor jack supporting the axle to create clearance between the axle and leaf spring. Lower only enough to separate the components by 2-3 inches.
5. 5

   Remove rear shackle bolts
   At the rear of the leaf spring, remove the two bolts securing the shackle to both the frame mount and the spring eye. Use the correct socket size per the service manual (these are large-diameter bolts, verify size before starting). Note the orientation of shackle plates for reassembly. The shackle should now be free.
6. 6

   Remove front spring eye bolt
   At the front of the leaf spring, remove the single bolt passing through the spring eye and frame bracket using the correct socket size per the service manual (verify size before starting). Support the spring as you remove this bolt to prevent it from falling.
7. 7

   Remove leaf spring assembly
   Carefully maneuver the leaf spring assembly out from between the frame and axle. It may be necessary to lower the axle further or use a pry bar to create clearance. Inspect the frame mounting points and brackets for damage or excessive rust.
8. 8

   Prepare new leaf spring
   Install new bushings in the front spring eye and rear spring eye of the new leaf spring assembly if not pre-installed. If using rubber OEM bushings, install dry. If using polyurethane bushings, apply the manufacturer-supplied polyurethane-safe lubricant to the bushings. Install new shackle plates and bushings to the rear spring eye.
9. 9

   Install front spring eye
   Maneuver the new leaf spring into position. Align the front spring eye with the frame bracket and insert the mounting bolt. Thread the nut on but do not fully tighten yet. Leave loose enough to allow pivoting.
10. 10

    Install rear shackle
    Align the rear shackle with both the spring eye and frame mount. Install both shackle bolts with nuts but do not fully tighten. Leave loose enough to allow the spring to move into position.
11. 11

    Align axle to spring
    Raise the floor jack to bring the axle up to the leaf spring. Align the center bolt of the spring with the locating hole in the axle pad. Ensure any spacer blocks are properly positioned. The spring should sit flat against the axle mounting surface.
12. 12

    Install U-bolts and backing plate
    Position the backing plate over the spring on top of the axle. Install both U-bolts through the backing plate and around the axle housing. Thread all four nuts onto the U-bolts finger tight, then tighten in a cross pattern to gradually clamp the assembly. Torque the U-bolt nuts to the manufacturer's specification (typically significantly higher than 110 ft-lb on these heavy-duty trucks — verify exact value in the service manual) in multiple passes using a cross pattern to ensure even clamping.
13. 13

    Reinstall shock absorber
    Align the lower shock mount with the axle bracket and install the mounting bolt and nut. Torque to specification per service manual (typically 70-80 ft-lb).
14. 14

    Reinstall wheel and lower vehicle
    Install the rear wheel and thread lug nuts by hand. Lower the vehicle so the suspension is at normal ride height with weight on the wheels, but keep jack stands in place for safety.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)
15. 15

    Final torque with weight on suspension
    With the vehicle at ride height, torque the front spring eye bolt and both rear shackle bolts to the manufacturer's specification (verify each value in the service manual — these differ and may exceed 110 ft-lb). This must be done with weight on the suspension to prevent bushing bind. Remove jack stands and lower vehicle completely. Torque wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. All spring mounting bolts must be torqued with vehicle weight on the suspension at normal ride height to prevent premature bushing failure
2. Ensure U-bolts are torqued evenly in a cross pattern to prevent spring distortion
3. Verify shock absorber is properly mounted and not binding through full suspension travel

Verification

• Test drive vehicle and verify no unusual noises or clunking from rear suspension
• Check that vehicle sits level side-to-side with no lean
• Re-torque U-bolt nuts after 50 miles of driving as springs settle
• Verify adequate clearance between leaf spring and frame through full suspension travel
• Check alignment if vehicle pulls to one side or shows uneven tire wear after replacement

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