Upper Control Arm - Front

This procedure covers the removal and replacement of the upper control arm on the front suspension of a 1994-2007 Dodge Ram 2500 with 4WD.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification or quality aftermarket
• Cotter pin (ball joint) × 1 — Standard 1/8 inch diameter

Preparation

1. Park vehicle on level ground and engage parking brake
2. Chock rear wheels securely
3. Loosen wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support on jack stands under the frame rails
5. Remove wheel and tire assembly
6. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Remove ball joint cotter pin
   Locate the upper ball joint where it attaches to the steering knuckle. Use needle nose pliers to straighten and remove the cotter pin from the ball joint castle nut. Discard the old cotter pin.
2. 2

   Loosen ball joint nut
   Using a socket and breaker bar, loosen the upper ball joint castle nut but do not remove it completely. Leave it threaded on a few turns to prevent the control arm from separating suddenly when the taper is broken.
3. 3

   Separate ball joint from knuckle
   Insert the ball joint separator (pickle fork) between the steering knuckle and upper control arm. Strike the separator with a hammer to break the taper seal. Once the joint is loose, remove the castle nut completely. Support the knuckle/hub assembly to prevent strain on the brake hose and axle components. Avoid hitting the axle shaft or brake components with the separator tool. Damage to these parts will require additional replacement.
   ⚠Avoid hitting the CV axle boot or brake components with the separator tool. Damage to these parts will require additional replacement.
4. 4

   Remove control arm front mounting bolt
   Locate the front control arm mounting bolt that attaches the control arm to the frame bracket. This bolt runs horizontally through the front bushing. Use a socket and breaker bar to remove the nut and bolt. Note the orientation of any washers or spacers for reinstallation.
5. 5

   Remove control arm rear mounting bolt
   Locate the rear control arm mounting bolt that attaches the control arm to the frame bracket. This bolt also runs horizontally through the rear bushing. Remove the nut and bolt. The control arm should now be free to remove from the vehicle.
6. 6

   Remove upper control arm
   Maneuver the upper control arm out of the mounting brackets and away from the steering knuckle. Inspect the mounting points on the frame for excessive wear, rust, or damage. Clean mounting surfaces with a wire brush.
7. 7

   Install new upper control arm
   Position the new upper control arm into the frame mounting brackets. Insert the front and rear mounting bolts through the bushings and frame brackets. Thread the nuts onto the bolts hand-tight only. Do NOT torque at this time - these must be torqued with vehicle weight on wheels.
8. 8

   Connect ball joint to knuckle
   Guide the ball joint stud into the steering knuckle taper. Ensure it seats fully into the taper. Install the castle nut and tighten to specification. The castellations must align with the cotter pin hole - if they do not align, tighten further (never loosen) until the next castellation aligns.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
9. 9

   Install new cotter pin
   Insert a new cotter pin through the castle nut and ball joint stud. Bend the ends of the cotter pin to secure it in place, ensuring it cannot back out.
10. 10

    Reinstall wheel and tire
    Mount the wheel and tire assembly. Install lug nuts and hand-tighten in a star pattern. Lower the vehicle until the tire just contacts the ground but the suspension is not yet loaded.
11. 11

    Torque control arm mounting bolts
    With the vehicle weight now on the wheels (suspension at ride height), torque the front and rear control arm mounting bolts to specification. This is critical for proper bushing life and alignment.
    ⚠Control arm bolts MUST be torqued at ride height. Torquing while suspended will preload the bushings incorrectly and cause premature failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
12. 12

    Final wheel torque
    Fully lower the vehicle to the ground. Torque the wheel lug nuts to specification in a star pattern to ensure even seating.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. Verify all fasteners are tight and properly torqued
2. Check that the cotter pin is properly installed and secured
3. Ensure no tools or parts were left in the wheel well

Verification

• Test drive the vehicle at low speed and verify no unusual noises or vibrations from the front suspension
• Check for proper steering response and wheel alignment
• Have the vehicle aligned by a professional alignment shop - control arm replacement will affect camber and caster settings
• Re-torque wheel lug nuts after 50-100 miles of driving

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