This procedure covers the removal and replacement of the front upper control arm on a 2014 Ram 2500 with 6.7L Cummins diesel engine and 4WD.

Warnings

Tools required

Parts

• Front upper control arm assembly × 1 — Use OEM specification or quality aftermarket
• Ball joint castle nut (if not reusable) × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Chock rear wheels securely
3. Loosen wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle with floor jack and support securely on jack stands placed on frame rails
5. Remove wheel and tire assembly completely
6. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes if corrosion is present

Procedure

1. 1

   Support the knuckle assembly
   Place a floor jack under the lower control arm or knuckle to support the suspension weight. Raise jack just enough to slightly compress the suspension and relieve tension on the upper control arm. This prevents the knuckle from dropping when the ball joint is disconnected.
2. 2

   Remove the upper ball joint castle nut
   Remove the cotter pin from the upper ball joint castle nut. Using an 18mm socket, remove the castle nut from the ball joint stud. Do not discard the nut if it is in good condition and the castle slots align properly with the cotter pin hole.
3. 3

   Separate the ball joint from the knuckle
   Using a ball joint separator tool or pickle fork, separate the upper ball joint stud from the steering knuckle. Position the tool between the knuckle and the control arm, then strike with a hammer or apply pressure until the taper releases. If using a pickle fork, note that this may damage the ball joint boot. Once separated, carefully lower the jack slightly to allow the knuckle to drop away from the control arm.
   ⚠The ball joint may release suddenly. Ensure the knuckle is supported and keep hands clear of pinch points.
4. 4

   Remove the front control arm-to-frame bolt
   Locate the front mounting bolt connecting the upper control arm to the frame bracket. Using a 21mm socket and breaker bar, remove the bolt completely. Note the orientation and position of any washers or sleeves for reinstallation.
5. 5

   Remove the rear control arm-to-frame bolt
   Locate the rear mounting bolt connecting the upper control arm to the frame bracket. Using a 21mm socket and breaker bar, remove the bolt completely. Support the control arm as you remove the final bolt to prevent it from falling.
6. 6

   Remove the upper control arm
   With both mounting bolts removed, carefully maneuver the upper control arm out of the frame brackets and away from the vehicle. Inspect the frame mounting points for corrosion, damage, or worn bushings. Clean mounting surfaces with a wire brush if necessary.
7. 7

   Prepare and position the new upper control arm
   Compare the new upper control arm to the old unit to verify correct fitment. Inspect the ball joint boot for damage and ensure bushings are properly seated. Position the new control arm into the frame brackets, aligning the mounting holes. Insert both front and rear mounting bolts by hand but do NOT tighten yet.
8. 8

   Connect the ball joint to the knuckle
   Raise the floor jack under the lower control arm to lift the steering knuckle up to the upper ball joint stud. Align the ball joint stud with the hole in the top of the knuckle and push the knuckle onto the taper. Install the castle nut onto the ball joint stud and tighten by hand initially.
9. 9

   Torque the ball joint nut
   Using a torque wrench and 18mm socket, torque the upper ball joint castle nut to specification. Ensure the castle slots align with the cotter pin hole. If necessary, tighten the nut slightly additional (never loosen) until alignment is achieved. Install a new cotter pin and bend the ends to secure.
   Torque spec

   Ball Joint Nut119 Nm (88 lb-ft)
10. 10

    Load the suspension to ride height
    Before final torquing of the control arm-to-frame bolts, the suspension must be at ride height to prevent bushing bind. Either lower the vehicle so the tires contact the ground with full vehicle weight, OR use a jack to raise the lower control arm until the suspension is at normal ride height position (wheel in normal driving position relative to fender).
    ⚠Failure to torque control arm bolts at ride height will cause premature bushing failure and handling issues.
11. 11

    Torque the control arm-to-frame bolts
    With the suspension loaded to ride height, torque both the front and rear control arm-to-frame mounting bolts to specification using a torque wrench and 21mm socket. Torque both bolts while maintaining ride height position.
    Torque spec

    Control Arm-to-Frame Bolts122 Nm (90 lb-ft)
12. 12

    Reinstall the wheel and tire
    If vehicle was lowered for torquing, raise it back up and remove the jack from under the suspension. Position the wheel onto the hub and install all lug nuts by hand. Tighten lug nuts in a star pattern with a wrench, then lower the vehicle to the ground.
13. 13

    Final torque wheel lug nuts
    With the vehicle on the ground, torque all wheel lug nuts to specification in a star pattern using a torque wrench and 21mm socket. Repeat the pattern to ensure even torque distribution.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. Double-check that all fasteners are torqued to specification, especially the ball joint nut and control arm mounting bolts
2. Verify the cotter pin is properly installed and bent in the ball joint castle nut
3. Remove jack stands and lower vehicle completely
4. Test drive vehicle at low speed and listen for any unusual noises from the front suspension
5. Perform a professional wheel alignment as soon as possible, as the upper control arm replacement will affect camber and caster angles

Verification

• Visually inspect that the upper control arm is properly seated in frame brackets with no gaps
• Confirm the ball joint stud is fully seated in the knuckle with castle nut torqued and cotter pin installed
• Check for any play in the ball joint by attempting to move the knuckle relative to the control arm by hand
• Test drive vehicle and verify no clunking, popping, or unusual noises from front suspension over bumps
• Schedule a wheel alignment within 50 miles of completing this repair to ensure proper tire wear and handling

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