Tie Rod End - Inner

Replace the inner tie rod end on a 1994-2007 Dodge Ram 2500 4WD with 5.9L Cummins diesel engine, requiring removal of the outer tie rod and adjustment sleeve to access the inner tie rod at the steering rack.

Warnings

Tools required

Parts

• Inner tie rod end × 1 — Use OEM specification or quality aftermarket
• Cotter pin × 1 — Appropriate size for outer tie rod castle nut
• Tie rod boot/bellows (if damaged) × 1 — Inspect and replace if torn

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels securely
3. Turn steering wheel to center position and lock ignition to prevent steering movement
4. Apply penetrating oil to tie rod end castle nut, adjustment sleeve jam nut, and inner tie rod threads at steering rack
5. Loosen wheel lug nuts while vehicle is on ground

Procedure

1. 1

   Raise and support vehicle
   Lift the front of the vehicle using a floor jack at the front axle differential. Place jack stands under the frame rails near the front axle. Remove the wheel and tire assembly on the side being serviced.
2. 2

   Mark alignment reference
   Before loosening any components, use a white paint marker or grease pencil to mark the position of the adjustment sleeve relative to both the inner and outer tie rod threads. Count and record the number of visible threads on the outer tie rod past the adjustment sleeve. This provides a rough reference for reassembly to minimize alignment deviation.
3. 3

   Remove outer tie rod end from knuckle
   Remove the cotter pin from the outer tie rod castle nut and discard. Remove the castle nut. Use a tie rod separator or pickle fork to separate the outer tie rod end stud from the steering knuckle. Strike the separator firmly with a hammer to break the taper loose. Avoid damaging the steering knuckle threads or boot.
   ⚠Using a pickle fork will likely destroy the tie rod end boot. Acceptable if replacing the tie rod end.
4. 4

   Loosen tie rod lock nut
   Locate the jam nut (lock nut) on the adjustment sleeve between the inner and outer tie rod ends. Use a large adjustable wrench or appropriately sized wrench to loosen this jam nut several turns. Do not remove completely yet.
5. 5

   Remove outer tie rod and adjustment sleeve
   While holding the adjustment sleeve stationary, unthread the outer tie rod end by turning it counterclockwise. Count the turns as you remove it. Once the outer tie rod is removed, unthread the adjustment sleeve from the inner tie rod, again counting turns and noting position.
6. 6

   Access inner tie rod at steering rack
   This vehicle uses a solid front axle with a recirculating-ball steering gearbox and a linkage-style tie rod (drag link / tie rod bar), NOT a rack-and-pinion system. The 'inner tie rod end' on this platform is the ball-stud joint at the end of the tie rod bar that connects to the steering knuckle or the adjuster sleeve, not a threaded rack joint. Inspect the ball-stud boot for tears or damage and clean dirt and debris from the tie rod threads and adjuster sleeve.
7. 7

   Remove inner tie rod end
   Remove the cotter pin and castle nut from the inner tie rod end ball stud. Use a tie rod separator or pickle fork to break the tapered stud loose from the steering knuckle (or the pitman arm connection, depending on linkage side). No inner-tie-rod crow's-foot tool is required on this solid-axle platform. Penetrating oil applied ahead of time will ease separation. Do not force the steering linkage or gearbox against its stops during removal. Keep the steering wheel centered and avoid over-torquing the linkage to prevent damaging the pitman arm or steering gearbox sector shaft.
   ⚠Do not allow the steering rack to rotate during inner tie rod removal as this can damage internal rack components.
8. 8

   Prepare new inner tie rod
   Clean the adjuster sleeve threads and the tapered stud bore in the knuckle with a wire brush. Ensure the new inner tie rod end matches the old part in stud taper, thread pitch, length, and design. No thread locker is used on the tapered ball-stud connection; it is secured with the castle nut and cotter pin.
9. 9

   Install new inner tie rod
   Insert the new inner tie rod end tapered stud into the steering knuckle (or pitman arm). Install the castle nut and tighten to the factory tie rod end nut specification, then continue tightening (never loosen) only as needed to align the cotter pin hole. Install a new cotter pin. Verify torque against the factory service manual before driving.nual for exact value or tighten firmly and verify with alignment shop.
10. 10

    Install adjustment sleeve and outer tie rod
    Thread the adjustment sleeve onto the new inner tie rod to approximately the same position as marked during disassembly. Thread the outer tie rod end into the adjustment sleeve, matching the same number of turns recorded during removal. This should position the outer tie rod stud approximately at the steering knuckle.
11. 11

    Connect outer tie rod to knuckle
    Insert the outer tie rod end stud into the steering knuckle. Install the castle nut and tighten to specification. The castle nut slots must align with the stud hole for cotter pin installation. If necessary, tighten slightly beyond specification (never loosen) to achieve alignment slot alignment. Install a new cotter pin and bend ends to secure.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
12. 12

    Reinstall wheel and lower vehicle
    Reinstall the wheel and tire assembly. Thread lug nuts by hand to prevent cross-threading. Tighten lug nuts in a star pattern to specification using a torque wrench. Lower the vehicle from jack stands and remove jack.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)
13. 13

    Final lug nut torque
    With the vehicle on the ground, perform a final torque check on all wheel lug nuts in a star pattern to ensure proper seating and torque specification.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. Do NOT tighten the tie rod lock nut at the adjustment sleeve until after professional alignment
2. The tie rod lock nut should be torqued to 68 Nm (50 ft-lb) after alignment is completed
3. Verify steering wheel returns to center and steering operates smoothly through full range of motion

Verification

• Check that all fasteners are torqued to specification and cotter pin is properly installed
• Verify no interference exists between tie rod components and suspension/chassis throughout steering travel
• Test drive vehicle at low speed in safe area to verify steering response before driving to alignment shop
• Have front-end alignment performed immediately - toe adjustment is critical after inner tie rod replacement
• After alignment, verify tie rod lock nut has been torqued to specification by alignment technician

More procedures for this vehicle