Tie Rod Assembly

Procedure to remove and replace the outer tie rod assembly on a 2008 Dodge Viper, including steering linkage separation and alignment preparation.

Warnings

Tools required

Parts

• Outer tie rod end assembly × 1 — Mopar 68049367AA or equivalent
• Castle nut (if damaged) × 1 — Use OEM specification
• Cotter pin × 1 — New cotter pin required

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Place wheel chocks behind rear wheels.
3. Loosen the front wheel lug nuts while vehicle is on the ground.
4. Raise the front of the vehicle using a floor jack at the front crossmember jack point.
5. Support vehicle securely on jack stands placed at the manufacturer-specified jacking points on the front subframe.
6. Remove the front wheel on the side requiring tie rod replacement.

Procedure

1. 1

   Mark tie rod position for alignment reference
   Before removing the tie rod, measure and record the exposed thread length from the inner tie rod jam nut to the outer tie rod end. Use a tape measure or caliper and record this measurement precisely. Mark the position of the outer tie rod relative to the inner tie rod using a paint marker across both components. This will allow approximate restoration of toe setting during installation.
2. 2

   Remove cotter pin and castle nut
   Locate the castle nut securing the outer tie rod end to the steering knuckle. Straighten and remove the cotter pin using pliers. Discard the cotter pin as it must be replaced. Remove the castle nut using the appropriate socket. Do not fully remove the nut yet; back it off until it is flush with the end of the stud to protect threads during separation.
3. 3

   Separate tie rod end from steering knuckle
   Apply penetrating oil around the tie rod taper where it enters the steering knuckle if the vehicle has significant mileage or corrosion. Insert the tie rod separator tool (pickle fork) between the steering knuckle and tie rod end ball joint. Strike the separator tool with a hammer to break the taper joint free. Alternatively, use a tie rod puller tool if available to avoid damaging the steering knuckle boot. Once the taper is broken, remove the castle nut completely and separate the tie rod end from the knuckle.
4. 4

   Loosen jam nut on inner tie rod
   Locate the jam nut (lock nut) on the inner tie rod where the outer tie rod threads onto it. This jam nut secures the outer tie rod adjustment. Use a wrench to loosen the jam nut while holding the outer tie rod end to prevent it from turning. Do not remove the jam nut completely; just break it loose.
5. 5

   Remove outer tie rod end
   Count and record the number of turns as you unthread the outer tie rod end from the inner tie rod assembly. Turn the outer tie rod end counterclockwise to remove it. Keep track of the exact number of complete rotations for installation reference. Once fully unthreaded, remove the jam nut from the inner tie rod and inspect the threads on the inner tie rod for damage.
6. 6

   Clean and inspect inner tie rod threads
   Use a wire brush to clean the threads on the inner tie rod assembly. Inspect for damage, corrosion, or stripping. Check the inner tie rod boot for tears or damage. If the boot is damaged or the inner tie rod shows excessive wear, the inner tie rod assembly should also be replaced (not covered in this procedure).
7. 7

   Install new outer tie rod end
   Thread the jam nut onto the inner tie rod first. Thread the new outer tie rod end onto the inner tie rod in the direction opposite of removal (typically clockwise for right-hand thread; verify thread direction observed during removal). Use the same number of turns recorded during removal, and align with the reference marks made earlier. The exposed thread length should match your initial measurement. This provides an approximate starting point for alignment.
8. 8

   Install tie rod end into steering knuckle
   Insert the tie rod end stud into the steering knuckle taper hole. Ensure the stud seats fully into the taper. Install the castle nut and tighten it to the factory-specified torque (verify exact spec for 2008 Viper in the service manual). If the castle nut slots do not align with the cotter pin hole, continue tightening the nut until the next slot aligns. Never loosen the nut to align the cotter pin hole.
9. 9

   Secure castle nut with new cotter pin
   Insert a new cotter pin through the castle nut slots and the hole in the tie rod stud. Bend the cotter pin ends in opposite directions to secure it. Ensure the cotter pin is fully seated and cannot work loose.
10. 10

    Tighten jam nut
    Hold the outer tie rod end firmly to prevent it from rotating. Tighten the jam nut against the outer tie rod end to the factory-specified torque (verify exact spec for 2008 Viper in the service manual). Verify that the outer tie rod end did not rotate during jam nut tightening by checking your alignment marks.
11. 11

    Reinstall wheel and lower vehicle
    Reinstall the front wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground but the suspension is not fully loaded. Torque the lug nuts to the factory-specified value (verify exact spec for 2008 Viper, then apply in a star pattern). Fully lower the vehicle and remove jack stands.

Reassembly

1. Installation is performed as part of the main procedure steps.
2. Ensure all fasteners are torqued to specification and the new cotter pin is properly installed.
3. Do not drive the vehicle at highway speeds until a professional alignment is completed.

Verification

• Verify the tie rod end ball joint is fully seated in the steering knuckle taper and the castle nut is secure.
• Verify the cotter pin is properly installed and bent to prevent loosening.
• Verify the jam nut is tight against the outer tie rod end and the tie rod cannot rotate freely.
• Start the engine and turn the steering wheel full lock left and right while stationary to verify no binding or unusual noise.
• Test drive at low speed in a safe area to verify steering responsiveness. The vehicle will likely pull to one side due to altered toe setting.
• Schedule a professional four-wheel alignment immediately after completing this repair.

More procedures for this vehicle