Ball Joint - Upper

This procedure covers removal and replacement of the upper ball joint on the front suspension of a 2007 Ram 3500 with the 5.9L Cummins diesel engine and 4WD.

Warnings

Tools required

Parts

• Upper ball joint × 1 — Use OEM specification or Moog K7460
• Cotter pin for ball joint castle nut × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and set parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on the ground (do not remove)
4. Raise front of vehicle with floor jack at frame rail
5. Support vehicle with jack stands rated for at least 10,000 lbs under frame rails
6. Remove front wheel and tire on side being serviced
7. Spray all ball joint and control arm fasteners with penetrating oil and allow to soak for 15-20 minutes

Procedure

1. 1

   Support the lower control arm
   Position a floor jack under the front axle housing near the knuckle to support the weight of the axle and maintain a stable working position. Raise the jack just enough to take up slack. This stabilizes the knuckle when the upper ball joint is disconnected.
2. 2

   Remove brake caliper
   Remove the two brake caliper mounting bolts and carefully hang the caliper assembly from the frame using wire or a bungee cord. Do not allow the caliper to hang by the brake hose. This provides clearance to access the upper ball joint and knuckle.
3. 3

   Disconnect ABS sensor wire
   Locate the ABS wheel speed sensor wire bracket on the steering knuckle. Remove the mounting bolt and carefully move the wire harness out of the way to prevent damage during ball joint removal.
4. 4

   Remove upper ball joint castle nut
   Remove the cotter pin from the upper ball joint castle nut using pliers or side cutters. Using a socket and breaker bar, remove the castle nut from the upper ball joint stud. Keep the nut nearby as you may need to thread it back on partially for the next step.
5. 5

   Separate upper ball joint from knuckle
   Use a pickle fork or ball joint separator tool to break the taper fit between the ball joint stud and the knuckle. Insert the separator tool between the knuckle and the axle yoke at the upper ball joint, then strike with a hammer or apply press force until the taper releases. Alternatively, use a ball joint separator/press tool. Once separated, support the knuckle assembly to prevent it from dropping.
   ⚠Do not strike the ball joint stud directly with a hammer as this can damage the threads or mushroom the stud end.
6. 6

   Remove the steering knuckle
   To remove the knuckle, disconnect the tie rod end, then remove the lower ball joint castle nut cotter pin and nut and separate the lower ball joint. With both upper and lower ball joints separated from the axle yoke, the knuckle can be removed. The unit bearing hub (three bolts) may remain on the knuckle or be removed separately for access.
7. 7

   Press out the old upper ball joint
   Using an on-vehicle ball joint press (C-frame) with appropriate adapters, position the tool on the axle yoke/knuckle. Verify correct pressing direction per the service manual before applying force. Select a receiver cup that fits around the ball joint body and a driver that contacts only the top of the ball joint. Apply steady pressure with the press to drive the old ball joint out of the knuckle bore. Clean the knuckle bore thoroughly with a wire brush and inspect for damage or excessive wear.
   ⚠Ensure the press adapters are properly sized and positioned to avoid damaging the knuckle bore. The driver must not contact the knuckle surface.
8. 8

   Inspect the knuckle bore
   Carefully inspect the ball joint bore in the knuckle for cracks, damage, or excessive wear. The bore should be smooth and round. Check that the snap ring groove (if equipped) is clean and undamaged. If the bore is damaged or out of round, the knuckle must be replaced.
9. 9

   Press in the new upper ball joint
   Position the new upper ball joint at the top of the knuckle bore with the stud facing down. Ensure the ball joint is properly aligned and seated squarely in the bore. Using the ball joint press with appropriate adapters, apply steady pressure to press the new ball joint into the knuckle until it is fully seated. The ball joint should press in smoothly and seat against the internal shoulder or snap ring groove in the knuckle.
   ⚠Do not press on the ball joint stud or dust boot. Apply pressure only to the outer body of the ball joint. Misalignment during pressing can damage the knuckle or ball joint.
10. 10

    Install snap ring if equipped
    If the ball joint uses a snap ring for retention, install the snap ring into the groove in the knuckle bore using snap ring pliers. Ensure the snap ring is fully seated in the groove around its entire circumference. Verify the ball joint cannot be pulled out of the knuckle.
11. 11

    Reinstall the steering knuckle
    If the knuckle was removed, position the upper and lower ball joint studs into the axle yoke and install the castle nuts finger tight. Reinstall the three unit bearing (hub) bolts if removed. Reconnect the tie rod end.
12. 12

    Install upper ball joint castle nut
    Thread the castle nut onto the upper ball joint stud and tighten using a torque wrench. Consult factory service manual for the proper torque specification for the 2007 Ram 3500 upper ball joint nut before final tightening. Continue tightening only as needed to align the next castle slot with the cotter pin hole in the stud. Install a new cotter pin and bend the ends to secure.
13. 13

    Lubricate ball joint
    If the new ball joint has a grease fitting (zerk), use a grease gun to pump chassis grease into the ball joint until fresh grease appears at the boot seal. Wipe away excess grease. Some ball joints are sealed and do not require lubrication.
14. 14

    Reinstall brake caliper and wheel
    Reinstall the brake caliper and torque the mounting bolts to specification. Reconnect the ABS sensor wire and secure the bracket. Remove the floor jack from under the lower control arm. Install the wheel and thread lug nuts by hand. Lower vehicle until tire contacts ground, then torque lug nuts in a star pattern to 145 ft-lbs (verify against factory service manual).

Reassembly

1. Verify all fasteners are properly torqued including ball joint castle nuts, control arm bolts, caliper bolts, and wheel lug nuts
2. Ensure new cotter pins are installed and properly bent on both upper and lower ball joint castle nuts
3. Check that ABS sensor wire is properly routed and secured to prevent damage
4. Pump brake pedal several times to ensure proper brake caliper piston position before moving vehicle

Verification

• Start engine and turn steering wheel full lock in both directions while stationary to verify no binding or interference
• Test drive vehicle at low speed in a safe area and check for unusual noises, vibrations, or handling issues
• After test drive, re-check all fastener torques, especially wheel lug nuts and ball joint castle nuts
• Schedule a professional front-end alignment as soon as possible, as suspension work affects wheel alignment angles
• Inspect ball joint dust boot for proper seating and no tears or damage
• After 50-100 miles of driving, re-torque wheel lug nuts and verify ball joint castle nut cotter pin is secure

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