Sway Bar - Front

This procedure covers removal and replacement of the front sway bar (stabilizer bar) and associated links on a 1994-2007 Dodge Ram 2500 4WD with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Front sway bar × 1 — Use OEM specification or equivalent
• Sway bar links (pair) × 2 — Use OEM specification or equivalent
• Sway bar bushings (pair) × 2 — Use OEM specification or equivalent
• Sway bar bracket bolts × 4 — Reuse if not corroded

Preparation

1. Park vehicle on level ground and engage parking brake
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle with floor jack at frame contact points
5. Support vehicle with jack stands under frame rails behind front axle
6. Remove both front wheels completely
7. Spray penetrating oil on sway bar link nuts and bracket bolts if fasteners show corrosion

Procedure

1. 1

   Remove driver side sway bar link
   Locate the sway bar link connecting the sway bar to the axle housing on the driver side. Remove the upper nut connecting the link to the sway bar using the appropriate wrench and socket sizes for your specific link hardware. If the link shaft spins, hold it with an Allen key from the backside. Remove the lower nut and detach the link completely. If the link shaft spins, hold it with an Allen key from the backside. Remove the lower nut and detach the link completely.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
2. 2

   Remove passenger side sway bar link
   Repeat the same process on the passenger side. Remove both the upper and lower nuts securing the sway bar link. Keep hardware organized if reusing. Note the orientation and any washers or bushings for reassembly.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
3. 3

   Remove sway bar bracket bolts
   Locate the sway bar mounting brackets bolted to the front axle or frame. There are typically two brackets, one on each side of the differential. Using a 15mm socket, remove the bolts securing each bracket to the frame. There are usually 2 bolts per bracket for a total of 4 bolts.
   Torque spec

   Sway Bar Bracket Bolts47 Nm (35 lb-ft)
4. 4

   Remove sway bar and brackets
   With all fasteners removed, carefully lower and remove the sway bar from the vehicle. The bar may need to be rotated or maneuvered around the axle housing and steering components. Remove the brackets and bushings from the sway bar. Inspect bushings for wear, cracking, or deterioration.
5. 5

   Inspect and clean mounting surfaces
   Clean the sway bar mounting surfaces on the frame with a wire brush. Remove rust, dirt, and old bushing material. Inspect the sway bar itself for cracks, bends, or damage. Check that the bar is straight and not deformed. If replacing the bar, transfer any necessary hardware from the old bar.
6. 6

   Install new bushings on sway bar
   Install new bushings onto the sway bar in the correct orientation. The split in the bushing should face toward the rear of the vehicle or as indicated by the bushing design. Apply a light coating of silicone grease to the inside of the bushings to prevent squeaking. Do not use petroleum-based grease as it degrades rubber.
7. 7

   Position sway bar and brackets
   Maneuver the sway bar into position under the vehicle, routing it around the axle housing and steering components. Position the bushings at the mounting locations. Install the brackets over the bushings, ensuring the bushing splits are oriented correctly. Hand-thread all bracket bolts before tightening any.
   Torque spec

   Sway Bar Bracket Bolts47 Nm (35 lb-ft)
8. 8

   Torque sway bar bracket bolts
   Using a torque wrench, tighten the sway bar bracket bolts to specification. Tighten in a crisscross pattern if the bracket has multiple bolts. Ensure brackets are seated flush and bushings are not twisted or pinched.
   Torque spec

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

   Install driver side sway bar link
   Position the new sway bar link between the sway bar and the axle mount. Install washers and bushings in the correct order as indicated by the replacement link instructions. Thread the nuts onto both ends hand-tight. If the shaft rotates during tightening, use an Allen key to hold it stationary.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
10. 10

    Install passenger side sway bar link
    Repeat the installation process for the passenger side link. Ensure all washers and bushings are in the correct sequence. Hand-tighten both nuts before final torquing.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)
11. 11

    Torque sway bar link nuts
    Using a torque wrench, tighten all four sway bar link nuts (two per side) to specification. Hold the link shaft with an Allen key if it rotates during torquing. Verify all connections are secure and hardware is properly seated.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)
12. 12

    Reinstall wheels and lower vehicle
    Reinstall both front wheels, hand-tightening the lug nuts in a star pattern. Lower the vehicle until the tires just contact the ground but the suspension is not fully loaded. 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. Ensure all fasteners are torqued to specification before test driving
2. Double-check that all tools and parts have been removed from under vehicle
3. If vehicle was from a rust-prone area, consider applying rust preventative spray to new hardware

Verification

• Test drive vehicle at low speed and verify no rattling or clunking noises from front suspension
• Perform figure-eight turns in a parking lot to verify sway bar is functioning properly and reducing body roll
• Recheck all fastener torque after 50-100 miles of driving
• Inspect for any fluid leaks that may have occurred during work
• Verify steering response feels normal and vehicle tracks straight

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