Shock Absorber Replacement

This procedure covers the removal and replacement of front and/or rear shock absorbers on a 1994-2007 Dodge Ram 2500 4WD with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Front shock absorbers × 2 — Use OEM specification or quality aftermarket (Bilstein, Rancho, KYB)
• Rear shock absorbers × 2 — Use OEM specification or quality aftermarket (Bilstein, Rancho, KYB)
• Upper mount self-locking nuts × 4 — M12 x 1.75 self-locking nut

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels if working on front, or front wheels if working on rear
3. Spray shock mounting bolts and nuts with penetrating oil if fasteners appear corroded
4. Gather all tools and new parts before beginning work

Procedure

1. 1

   Raise and support vehicle
   Using the floor jack, raise the corner of the vehicle where shock replacement will occur. Position jack stands under the frame rail at approved jacking points. Lower vehicle onto jack stands. The suspension should be at full droop to relieve tension on the shock absorbers. Do not place jack stands under axle components.
2. 2

   Access upper shock mount (front shocks)
   For front shocks, locate the upper shock mount at the frame bracket above the front axle on each side. Access to the upper mount stud/nut is typically from within the wheel well or from underneath the vehicle, not through the engine bay. Clean any dirt or debris from around the upper mount nut. Clean any dirt or debris from around the upper mount nut.
3. 3

   Access upper shock mount (rear shocks)
   For rear shocks, locate the upper shock mount on the frame rail just forward of the rear axle. Access is from underneath the vehicle. On some configurations, the spare tire carrier may need to be lowered for better access.
4. 4

   Remove upper shock mount nut
   Using a 19mm wrench, hold the shock shaft from spinning while removing the upper mount nut with an 18mm socket. Discard the old self-locking nut; it must be replaced with a new one. If the shock spins freely, use locking pliers on the shaft flat if equipped, or hold the shock body from below.
5. 5

   Remove lower shock mount bolt
   Locate the lower shock mount bolt that attaches the shock to the axle bracket. Use a 21mm socket to remove the lower mount bolt. Support the shock absorber as you remove the bolt to prevent it from falling. The lower bolt passes through bushings in the shock eye and the axle mounting bracket.
6. 6

   Remove shock absorber
   Once both upper and lower fasteners are removed, carefully extract the shock absorber from the vehicle. For front shocks, maneuver the shock down and clear of the axle bracket and frame mount. For rear shocks, maneuver the shock clear of the axle and frame. Inspect mounting bushings and hardware for wear or damage.
7. 7

   Prepare new shock absorber
   Remove new shock from packaging. Check that new shock compresses and extends smoothly. Verify that all mounting bushings and hardware are included. Some shocks come pre-compressed with a shipping strap; remove this strap before installation. Do not extend gas-charged shocks to full length multiple times before installation.
8. 8

   Install new shock absorber
   Position the new shock absorber into place with the upper stud passing through the frame mount hole. Guide the lower shock eye onto the axle mounting bracket. Insert the lower mount bolt through the bracket and shock eye, ensuring washers are positioned correctly. Thread the bolt but do not fully tighten yet.
9. 9

   Install new upper mount nut
   Thread a NEW self-locking nut onto the upper shock stud. Hold the shock shaft from rotating using a 19mm wrench on the shaft hex (if accessible). Hand-thread the nut until snug, but do not torque yet.
   Torque spec

   Upper Mount Nut55 Nm (41 lb-ft)
10. 10

    Torque upper mount nut
    Using a torque wrench and 18mm socket, torque the upper mount nut to 55 Nm (41 lb-ft) while holding the shock shaft with a 19mm wrench to prevent rotation. Ensure the self-locking nut seats properly against the mounting surface.
    Torque spec

    Upper Mount Nut55 Nm (41 lb-ft)
11. 11

    Torque lower mount bolt
    Using a torque wrench and 21mm socket, torque the lower mount bolt to 90 Nm (66 lb-ft). Ensure the bolt threads are clean and the bolt passes through all components correctly. The shock bushings should compress slightly when torqued to specification.
    Torque spec

    Lower Mount Bolt90 Nm (66 lb-ft)
12. 12

    Repeat for remaining shocks
    Repeat steps 2 through 11 for each remaining shock absorber to be replaced. It is recommended to replace shocks in axle pairs (both front or both rear) to maintain balanced handling and ride quality.
13. 13

    Lower vehicle
    Raise the vehicle slightly with the floor jack to unload the jack stands, then remove the jack stands. Carefully lower the vehicle completely to the ground. Rock the vehicle side-to-side to settle the suspension into its normal position.

Reassembly

1. Ensure all fasteners are torqued to specification
2. Verify new self-locking nuts were used on upper mounts
3. Confirm no tools or parts were left in wheel wells or under vehicle
4. Double-check that shock absorbers are fully seated at both upper and lower mounts

Verification

• Visually inspect all shock mounts to confirm proper installation and torque
• Bounce each corner of the vehicle to verify shocks are functioning - vehicle should return to normal ride height without excessive bouncing
• Test drive vehicle at low speed and verify improved ride quality and no unusual noises from shock mounts
• Re-check torque on all fasteners after first 50 miles of driving

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