Strut Assembly - Rear

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

Warnings

Tools required

Parts

• Rear strut assembly (complete with spring) × 2 — Use OEM specification or quality aftermarket
• Strut mounting hardware kit × 1 — Often included with strut assembly

Preparation

1. Park vehicle on level, solid surface and apply parking brake
2. Place wheel chocks in front of both front wheels
3. If bolts appear corroded, spray all strut mounting points with penetrating oil and allow to soak
4. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground
5. Raise rear of vehicle using floor jack at rear differential or frame rails
6. Support vehicle securely on jack stands rated for at least 6000 lbs, positioned under frame rails near rear axle
7. Remove rear wheels completely and set aside
8. Visually inspect strut mounting points for rust, damage, or seized hardware

Procedure

1. 1

   Access upper strut mounting nuts
   Locate the upper rear shock absorber mounting point on the frame bracket. Access is from underneath the vehicle. Clean any dirt or debris from the mounting area. Note the configuration of washers, bushings, and hardware for reassembly.
2. 2

   Support rear axle
   Position a floor jack under the rear axle near the strut being replaced. Raise the jack just enough to slightly compress the suspension and take tension off the strut. This prevents the axle from dropping when the strut is removed. Do not lift the vehicle off the jack stands.
   ⚠The jack is only supporting the axle, not the vehicle weight. Ensure jack stands remain securely under frame rails supporting the full vehicle weight.
3. 3

   Remove sway bar link if equipped
   If the rear sway bar link attaches to the strut or interferes with removal, disconnect it at the strut connection point. Use a wrench to hold the link shaft while loosening the nut to prevent spinning. Support the link to prevent strain on the opposite connection.
4. 4

   Remove lower strut mounting bolts
   Locate the lower shock absorber mounting bolt at the axle spring-plate/lower bracket. Use a breaker bar if necessary to break torque on the fastener. Remove the bolt completely. Support the shock to prevent it from falling once the upper mount is released.
   ⚠These bolts may be extremely tight or corroded. Ensure you have solid footing and proper leverage before applying force.
5. 5

   Remove upper strut mounting nuts
   While supporting the shock absorber, remove the upper mounting nut/bolt from the frame bracket. Keep track of all washers and rubber bushings for comparison with new parts.
6. 6

   Remove strut assembly
   Carefully lower the strut assembly from the vehicle. The strut may need to be angled or maneuvered to clear the frame and body. Watch for any brake lines or wiring that may be clipped to the strut body. Set the old strut aside for comparison with new assembly.
7. 7

   Inspect mounting points and hardware
   Thoroughly inspect the upper strut tower for rust, cracks, or damage. Inspect the lower axle mounting bracket for wear or damage. Clean all mounting surfaces with a wire brush. Check that new strut mounting hardware matches original configuration. Replace any corroded or damaged mounting hardware.
   ⚠Rust or damage to mounting points can compromise strut retention. If mounting points show significant deterioration, consult a qualified technician before proceeding.
8. 8

   Install new strut assembly - upper mount
   Position the new shock absorber into place, aligning the upper mounting stud/eye with the frame bracket. Install the upper mounting nut/bolt finger-tight only at this stage.
9. 9

   Install new strut assembly - lower mount
   Use the floor jack to raise the axle and align the lower strut mounting holes with the axle bracket. Install the lower strut-to-axle bolts and start the nuts finger-tight. Verify proper alignment before proceeding to final torque.
10. 10

    Torque lower strut mounting bolts
    With the suspension still supported by the jack at normal ride height position, torque the lower strut-to-axle bolts to specification. Torque in a crossing pattern if multiple bolts are present to ensure even loading.
    ⚠CRITICAL: These bolts must be torqued to exact specification. Under-torquing can allow bolts to loosen; over-torquing can cause fastener failure.
11. 11

    Torque upper strut mounting nuts
    Torque the upper shock mounting nut/bolt to specification. Do not over-torque as this can damage the rubber isolation bushing.
12. 12

    Reconnect sway bar link if equipped
    If the sway bar link was disconnected, reconnect it to the strut or axle mounting point. Hold the link shaft with a wrench while torquing the nut to specification to prevent the shaft from spinning.
13. 13

    Repeat for opposite side
    Perform steps 1-12 for the strut on the opposite side of the vehicle. Always replace struts in pairs to maintain balanced suspension performance and handling characteristics.
    ℹ️Never replace only one strut. Uneven suspension damping can cause unpredictable handling and premature tire wear.
14. 14

    Install wheels and lower vehicle
    Reinstall both rear wheels and start lug nuts by hand. Lower the vehicle carefully by raising the jack slightly to unload the jack stands, removing the stands, then lowering completely to the ground. Remove the floor jack from under the axle.
15. 15

    Final torque wheel lug nuts
    With the vehicle on the ground, torque the wheel lug nuts to specification in a star pattern. This ensures even pressure on the wheel and prevents warping of brake rotors or drums.
    ⚠Improper lug nut torque can cause wheel detachment or brake component damage. Always use a calibrated torque wrench.

Reassembly

1. Ensure all fasteners have been torqued to specification
2. Verify no tools or parts have been left in the wheel wells or suspension area
3. Check that brake lines and ABS wiring are properly routed and secured, not rubbing on new struts
4. Bounce each corner of the vehicle several times to settle the suspension and verify proper operation

Verification

• Start the vehicle and verify no warning lights appear on the dashboard
• Drive the vehicle slowly in a safe area and listen for any unusual noises from the rear suspension
• Verify the vehicle sits level from side to side and front to rear
• Test drive at various speeds and over bumps to confirm improved ride quality and proper damping
• After 50-100 miles of driving, re-torque all suspension fasteners to specification
• Have a professional alignment performed if vehicle pulls to one side or tire wear is uneven
• Visually inspect all mounting points after first few drives to ensure no loosening has occurred

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