Wheel Alignment

This procedure performs a complete four-wheel alignment on a 1994-2007 Dodge Ram 2500 4WD with the 5.9L Cummins diesel engine, adjusting toe, camber, and caster to factory specifications.

Warnings

Tools required

Parts

• Alignment cam bolts (if worn or seized) × 4 — Mopar 52088860AB or equivalent
• Tie rod boots (if damaged) × 2 — Inspect during procedure

Preparation

1. Verify all suspension components are in good working order (ball joints, tie rod ends, control arm bushings, steering linkage)
2. Check tire pressures and inflate all tires to specification (typically 50 psi front, 65 psi rear for this vehicle)
3. Inspect tires for uneven wear patterns that may indicate existing alignment issues
4. Park vehicle on level alignment rack surface
5. Bounce each corner of the vehicle several times to settle suspension before measurements
6. Place wheel chocks behind rear wheels
7. Apply penetrating oil to cam bolts and tie rod jam nuts if visible corrosion is present

Procedure

1. 1

   Mount alignment equipment and perform initial measurement
   Attach alignment heads or targets to all four wheels according to alignment machine manufacturer's instructions. Ensure sensors are properly calibrated. Perform a rolling compensation procedure by moving the vehicle forward and backward as directed by the machine. Take initial readings of camber, caster, and toe on all four wheels. Record measurements and compare to factory specifications.
2. 2

   Adjust rear axle toe (if required)
   On solid rear axles like the Ram 2500, rear toe is typically set by the axle position and is not adjustable. Verify rear axle is square to the frame by measuring from a fixed point on the frame to both rear wheel centers. If rear axle is out of square, inspect for bent axle housing, damaged leaf spring mounts, or shifted spring perches. Minor rear toe issues may indicate frame or axle damage requiring repair before proceeding.
   ℹ️Rear camber and toe are not adjustable on solid axle; out-of-spec readings indicate damaged components
3. 3

   Adjust front camber (driver side)
   The 1994-2007 Ram 2500 4WD uses a solid front axle (Dana 60), so camber and caster are adjusted using an eccentric offset (cam) sleeve installed at the upper ball joint, not via control arm cam bolts. Loosen the upper ball joint pinch/castle nut on the driver side and install or rotate the offset ball joint sleeve to adjust camber. Adjust to factory specification (verify exact spec for model year; typically near 0° ± 0.50° camber). Once in spec, torque the ball joint nut to specification while holding position.ive camber). Once in spec, torque cam bolts to specification while holding the cam in position.
   Torque spec

   Cam Bolts129 Nm (95 lb-ft)
4. 4

   Adjust front caster (driver side)
   Caster on the solid front axle is adjusted by rotating the eccentric offset ball joint sleeve orientation and/or, where equipped, adjustable control arm cams at the axle mounts. Verify factory caster specification for the specific model year (commonly a positive caster spec) and adjust accordingly. Balance camber and caster as they are interrelated through the offset sleeve, then torque the ball joint nut and any control arm cam bolts to specification after final adjustment.
   Torque spec

   Cam Bolts129 Nm (95 lb-ft)
5. 5

   Adjust front camber and caster (passenger side)
   Repeat the camber and caster adjustment procedure on the passenger side offset ball joint sleeve (and control arm cams if equipped). Aim for cross-camber (side-to-side difference) of less than 0.5° and cross-caster of less than 0.5° for optimal handling and tire wear. Torque the ball joint nut and any cam bolts to specification after achieving proper alignment angles.
   ⚠Cam bolts must be torqued while holding cam position to prevent movement during tightening
   Torque spec

   Cam Bolts129 Nm (95 lb-ft)
6. 6

   Check alignment readings after camber/caster adjustment
   Bounce front end of vehicle several times to settle suspension after cam bolt adjustments. Re-check camber and caster readings on alignment machine to verify adjustments held during torquing. Make fine adjustments if necessary. Verify both front wheels are within specification before proceeding to toe adjustment.
7. 7

   Adjust front toe (driver side)
   Loosen the adjusting sleeve clamp bolts on the tie rod adjusting sleeve. Rotate the adjusting sleeve to adjust toe; rotating to shorten the tie rod creates toe-in, lengthening creates toe-out. Verify correct wrench/socket size for the clamp bolts on your linkage before loosening. Factory specification is typically 0.10° ± 0.10° total toe (0.05° per wheel). Adjust until driver side toe is within specification.
   ℹ️Count turns of the tie rod for reference in case adjustment needs to be reversed
   Torque spec

   Tie Rod Jam Nuts55 Nm (41 lb-ft)
8. 8

   Adjust front toe (passenger side)
   After setting total toe with the tie rod adjusting sleeve, verify the steering wheel is centered when the wheels point straight ahead. If the steering wheel is off-center, adjust the drag link adjusting sleeve to re-center the steering wheel without changing total toe. Torque all adjusting sleeve clamp bolts to specification when complete.ation.
   Torque spec

   Tie Rod Jam Nuts55 Nm (41 lb-ft)
9. 9

   Final alignment verification
   Bounce all four corners of the vehicle to settle suspension after all adjustments. Perform final alignment readings on all four wheels. Verify all angles are within factory specifications: camber, caster, toe, and steering axis inclination (SAI). Check that steering wheel is centered. Print alignment report showing before and after measurements.
10. 10

    Remove alignment equipment and perform road test
    Remove all alignment heads or targets from wheels. Torque all wheel lug nuts to specification in a star pattern. Remove vehicle from alignment rack. Test drive vehicle on a straight, level road to verify steering wheel is centered, vehicle tracks straight without pulling, and there are no unusual handling characteristics. Re-check alignment if any issues are noted.
    ⚠Test at moderate speeds first to ensure vehicle handles predictably before highway speeds
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. Ensure all cam bolts are torqued to 129 Nm (95 lb-ft) with cams held in proper position
2. Verify all tie rod jam nuts are torqued to 55 Nm (41 lb-ft) to prevent toe change during operation
3. Confirm wheel lug nuts are torqued to 183 Nm (135 lb-ft) in star pattern
4. Inspect tie rod boots for damage that may have occurred during adjustment; replace if torn

Verification

• Alignment report shows all four wheels within factory specifications for camber, caster, and toe
• Steering wheel is centered when driving straight on level road
• Vehicle does not pull to either side under acceleration or braking
• No unusual tire scrubbing sounds during turns
• Test drive confirms stable, predictable handling characteristics

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