Tie Rod Assembly

This procedure covers removal and replacement of the tie rod assembly on a 1994-2007 Dodge Ram 2500 4WD with 5.9L Cummins diesel engine, including outer tie rod ends and adjustment sleeves.

Warnings

Tools required

Parts

• Tie rod end (left side) × 1 — Use OEM specification
• Tie rod end (right side) × 1 — Use OEM specification
• Cotter pins (1/8 inch) × 2 — Standard 1/8 inch castle nut cotter pins
• Tie rod assembly (complete if replacing entire assembly) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, paved surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on the ground (do not remove)
4. Raise front of vehicle with floor jack at frame rail and support on jack stands under frame
5. Remove front wheels completely
6. Spray all tie rod end nuts and adjustment sleeve threads with penetrating oil and let soak for 10-15 minutes

Procedure

1. 1

   Mark tie rod position for reference
   Before loosening anything, use a white paint marker or tape measure to mark the position of each tie rod end relative to the adjustment sleeve. Measure from the inner boot to the center of the outer tie rod end stud, and record this measurement. This will help approximate the alignment for driving to an alignment shop. Also count and record the number of threads visible on each tie rod end.
2. 2

   Remove cotter pins from tie rod ends
   Locate the castle nut on each outer tie rod end where it connects to the steering knuckle. Use needle nose pliers to straighten and remove the cotter pin from each side. Discard the old cotter pins as they should not be reused. 22mm socket and ratchet (lug nuts) — verify size against your specific wheels
3. 3

   Remove tie rod end castle nuts
   Using the correct size wrench or socket (verify against the FSM for your specific year and linkage type), remove the castle nut from each tie rod end. Do not remove the tie rod ends from the knuckle taper yet. Leave the nut threaded on a few turns to protect the threads and catch the tie rod end when the taper breaks free.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
4. 4

   Separate tie rod ends from steering knuckles
   Position a tie rod end puller or pickle fork between the steering knuckle and the tie rod end. Tighten the puller or strike the pickle fork with a hammer to break the taper loose. The tie rod end will pop free suddenly. Remove the castle nut completely and remove the tie rod end from the knuckle. Repeat for the other side.
   ⚠The tie rod end will release suddenly. Keep hands clear and support the tie rod to prevent it from falling.
5. 5

   Loosen tie rod lock nuts on adjustment sleeves
   Locate the adjustment sleeve connecting the inner and outer tie rod sections. There are jam nuts (lock nuts) on each end of the sleeve. Use an adjustable wrench to loosen these lock nuts but do not remove them yet. On these Ram 2500 models, the tie rod uses a threaded adjuster sleeve secured by jam nuts (lock nuts) on each end. Confirm the linkage style for your specific model year (Y-style pre-2003 vs T-style 2003+) before proceeding.
6. 6

   Remove outer tie rod ends from adjustment sleeves
   Unscrew the outer tie rod ends from the adjustment sleeves by turning them counterclockwise. Count the number of turns required to remove each side and record this information. Use a pipe wrench on the tie rod body if necessary, avoiding the threaded area. Remove both outer tie rod ends.
7. 7

   Inspect and clean threads
   Inspect the threads on the adjustment sleeves and inner tie rod sections for damage, rust, or debris. Use a wire brush to clean all threads thoroughly. Check the condition of the steering knuckle tapers and clean any dirt or grease. If replacing the entire tie rod assembly, disconnect the inner tie rod from the steering gear at this point.
8. 8

   Install new outer tie rod ends
   Thread the new outer tie rod ends into the adjustment sleeves by hand, turning them in the same number of turns recorded during removal, or matching the measurement marks made earlier. This provides an approximate starting point for alignment. Do not tighten the lock nuts yet. Ensure tie rod ends are threaded in at least 3/4 of an inch for safety.
9. 9

   Install tie rod ends into steering knuckles
   Insert the tie rod end studs into the steering knuckle tapers. Ensure the taper is seated properly and the stud is fully inserted. Thread the castle nuts onto the studs by hand as far as possible.
10. 10

    Torque castle nuts and install cotter pins
    Using a torque wrench, tighten each tie rod end castle nut to the factory specification (verify against the FSM for your specific year, typically approximately 75 Nm / 55 lb-ft for the Ram 2500 4WD). After reaching torque, check the alignment of the cotter pin hole in the stud with the castle nut slots. If they do not align, tighten the nut further (up to 1/6 turn additional) until the next slot aligns with the hole. Never loosen to align. Install new cotter pins through the castle nut slots and stud holes, then bend the ends to secure.
    ⚠Never loosen a castle nut to align the cotter pin hole. Only tighten further until alignment occurs.
    Torque spec

    Tie Rod End Nut54 Nm (40 lb-ft)
11. 11

    Tighten adjustment sleeve lock nuts (preliminary)
    Hand-tighten the lock nuts on the adjustment sleeves snugly, but do not torque them to final specification yet. If using clamp-style sleeves, ensure the clamp opening is positioned toward the rear of the vehicle and clamp bolts are snug. Final torquing will be done after professional alignment.
12. 12

    Reinstall wheels
    Place the front wheels back onto the hubs and thread all lug nuts on by hand. Lower the vehicle until the tires just touch the ground but the suspension is not fully loaded. This prevents wheel spinning while torquing lug nuts.
13. 13

    Torque wheel lug nuts
    Using a torque wrench, tighten the wheel lug nuts in a star pattern to the factory specification (typically approximately 176 Nm / 130 lb-ft for the Ram 2500 — verify against the FSM for your specific wheel/stud size). Fully lower the vehicle to the ground and remove jack stands. Re-torque lug nuts in star pattern to verify proper torque.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. Verify all cotter pins are properly installed and bent to prevent backing out
2. Check that adjustment sleeve clamps (if equipped) are oriented correctly with opening toward rear
3. Ensure no tools or parts have been left in the wheel well area

Verification

• Perform a visual inspection of all tie rod connections to ensure proper installation
• Turn the steering wheel lock-to-lock while stationary to check for binding or interference
• Test drive the vehicle at low speed in a safe area to verify steering response - vehicle will likely pull to one side due to alignment being out
• Schedule and complete a professional 4-wheel alignment immediately - this is essential for safety and tire wear
• After alignment is completed, verify the tie rod lock nuts have been torqued to final specification of 68 Nm (50 lb-ft)
• Re-check wheel lug nut torque after 50 miles of driving

More procedures for this vehicle