Sway Bar Bushing - Front

Replace worn front sway bar bushings to restore proper suspension articulation and eliminate clunking noises on this 4WD Dodge Ram 2500 with 5.9L Cummins diesel.

Warnings

Tools required

Parts

• Front sway bar bushing set (2 bushings) × 1 — Use OEM specification or Moog K200138
• Sway bar bushing bracket bolts (if corroded) × 4 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts 1/4 turn before raising vehicle
4. Apply penetrating oil to sway bar bracket bolts and allow to soak for 15-20 minutes if vehicle is from salt belt region

Procedure

1. 1

   Raise and support vehicle
   Raise front of vehicle with floor jack at frame rail or front differential. Place jack stands under frame rails on both sides. Remove both front wheels completely and set aside. Ensure vehicle is stable before proceeding under it.
2. 2

   Locate sway bar and bushings
   From underneath vehicle, locate the front sway bar running laterally across the front axle. Identify the two bushing brackets that secure the sway bar to the frame rail. The brackets are D-shaped clamps held by two bolts each.
3. 3

   Remove driver side bushing bracket
   Using appropriate socket, remove the two bolts securing the driver side sway bar bushing bracket. The bracket may be tight against the bushing; gently pry it away if necessary. Remove bracket and old bushing from sway bar. Note the orientation of the bushing split (typically faces toward rear of vehicle).
4. 4

   Remove passenger side bushing bracket
   Repeat removal process for passenger side bushing bracket. Remove both bolts, bracket, and old bushing. The sway bar may drop slightly once both bushings are removed; this is normal.
5. 5

   Clean sway bar mounting surfaces
   Use wire brush to clean the sway bar surface where bushings mount. Remove all rust, debris, and old bushing material. Clean the bracket mounting surfaces on the frame. Inspect sway bar for cracks or damage; replace if any damage is found.
6. 6

   Inspect and clean brackets
   Inspect bushing brackets for cracks, elongated bolt holes, or severe corrosion. Clean brackets with wire brush. Chase bracket bolt threads with penetrating oil if corroded. Replace brackets if damaged.
7. 7

   Install new driver side bushing
   Position new bushing around sway bar with the split facing toward rear of vehicle (or match original orientation if different). The bushing should fit snugly around the bar. Place bracket over bushing and align with mounting holes. Start both bracket bolts by hand to ensure proper thread engagement.
8. 8

   Torque driver side bracket bolts
   Using torque wrench, tighten driver side bushing bracket bolts to specification in a cross pattern (alternate between bolts). Ensure bushing is properly seated and centered on sway bar before final torquing.
   Torque spec

   Sway Bar Bracket Bolts47 Nm (35 lb-ft)
9. 9

   Install new passenger side bushing
   Position new bushing around sway bar on passenger side with split facing toward rear. Place bracket over bushing and align with mounting holes. Start both bracket bolts by hand.
10. 10

    Torque passenger side bracket bolts
    Using torque wrench, tighten passenger side bushing bracket bolts to specification in a cross pattern. Verify bushing is properly seated and not twisted or pinched.
    Torque spec

    Sway Bar Bracket Bolts47 Nm (35 lb-ft)
11. 11

    Reinstall wheels
    Mount both front wheels onto hubs. Thread lug nuts by hand first to prevent cross-threading. Snug lug nuts in star pattern with breaker bar but do not fully torque yet.
12. 12

    Lower vehicle and final torque
    Carefully remove jack stands and lower vehicle to ground. With full weight on wheels, torque wheel lug nuts to specification in star pattern using torque wrench.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. Ensure both bushing brackets are torqued to specification before operating vehicle
2. Check that no tools or parts were left under vehicle
3. Verify sway bar moves freely without binding on new bushings

Verification

• Test drive vehicle at low speed over bumps and during turning to verify elimination of clunking noises
• Visually inspect bushing brackets after 50-100 miles to ensure bolts remain tight
• Listen for any unusual noises from front suspension during normal driving
• Verify proper handling and stability during cornering maneuvers

More procedures for this vehicle