Ball Joints - Upper and Lower

This procedure covers removal and replacement of the upper and lower ball joints 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 (per side) × 2 — Moog K7460 or equivalent
• Lower ball joint (per side) × 2 — Moog K7397 or equivalent
• Cotter pins (assorted) × 8 — Use OEM specification
• Anti-seize compound × 1 — Use high-temp variety

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on ground (1/2 turn each)
4. Raise front of vehicle with floor jack and support on heavy-duty jack stands under frame rails behind lower control arms
5. Remove front wheels completely
6. Spray all ball joint castle nuts, control arm bolts, and steering linkage connections with penetrating oil and allow to soak for 15-20 minutes
7. Verify jack stands are secure and vehicle is stable before working underneath

Procedure

1. 1

   Disconnect steering linkage
   Remove cotter pin from tie rod end castle nut at the steering knuckle. Using a wrench, loosen and remove the castle nut. Use a pickle fork or ball joint separator tool to separate the tie rod end from the steering knuckle. Be careful not to damage the tie rod boot. Secure the tie rod out of the way to provide working clearance.
2. 2

   Remove brake caliper and rotor
   Remove the two brake caliper mounting bolts from the rear of the caliper bracket. Carefully lift the caliper assembly off the rotor without letting it hang by the brake hose. Support the caliper using wire or a bungee cord attached to the frame or suspension. Remove the brake rotor from the hub by pulling it straight off. If rotor is stuck, use penetrating oil and light tapping with a rubber mallet.
3. 3

   Remove ABS sensor wire
   If equipped with ABS, locate the wheel speed sensor wire and carefully disconnect it from the sensor at the steering knuckle. Unbolt any wire routing clips along the knuckle and axle housing to provide clearance for knuckle removal. Route the wire away from the work area to prevent damage.
4. 4

   Support lower control arm
   Support the front axle and knuckle appropriately for a solid-axle Dana front axle. The ball joints connect the steering knuckle to the axle tube yoke ends and do not carry coil spring load; ensure the knuckle is supported so it does not fall when the joints are separated.
5. 5

   Disconnect upper ball joint from knuckle
   Remove the cotter pin from the upper ball joint castle nut. Using a breaker bar and deep socket, loosen and remove the castle nut. Leave the nut threaded on by a few turns to protect the ball joint stud threads. Strike the steering knuckle boss area near the ball joint with a ball peen hammer to shock the taper loose. Once loose, remove the castle nut completely. If hammering does not work, use a pickle fork or separator tool, being careful not to damage the control arm or dust boot if reusing the ball joint.
   ⚠Keep the castle nut threaded on initially to prevent sudden separation that could cause injury or damage.
6. 6

   Disconnect lower ball joint from knuckle
   Remove the cotter pin from the lower ball joint castle nut. Use a breaker bar to loosen and remove the lower castle nut, leaving it threaded on a few turns initially. Strike the knuckle boss near the lower ball joint to break the taper loose. Once the taper is broken, remove the castle nut completely. Carefully support and pivot the steering knuckle away from the axle yoke to separate it from the lower ball joint.
7. 7

   Remove steering knuckle assembly
   With both upper and lower ball joints disconnected, carefully maneuver the steering knuckle and hub assembly away from the axle tube yoke. You may need to rotate the knuckle and work it past the axle shaft and other suspension components. Once clear, remove the knuckle from the vehicle and place it on a clean work surface. This provides access to press out the old ball joints.
8. 8

   Press out old upper ball joint
   Using a ball joint press kit, position the knuckle so the upper ball joint can be pressed out downward. Select the appropriate receiver cup that fits around the ball joint body and a driver that contacts only the ball joint housing, not the knuckle. Apply steady pressure with the press to drive the upper ball joint out of the knuckle bore. If resistance is extreme, apply heat to the knuckle ears around the ball joint (not the ball joint itself) to 300-350°F to aid removal.
   ⚠Ensure press adapters are properly aligned and contact only the ball joint, not the knuckle casting, to prevent cracking the knuckle.
9. 9

   Press out old lower ball joint
   Reposition the knuckle to press out the lower ball joint. The lower joint typically presses out upward through the knuckle. Again, select proper receiver and driver adapters sized for the lower ball joint. Apply steady force with the ball joint press to remove the old lower ball joint from the knuckle bore. Clean the ball joint bores in the knuckle thoroughly with a wire brush and remove any rust, debris, or old sealant.
10. 10

    Install new lower ball joint
    Verify the new lower ball joint matches the old one in size and design. Apply a thin coat of anti-seize compound to the outer surface of the ball joint housing. Position the new lower ball joint in the knuckle bore with the stud facing the correct direction (downward). Using the ball joint press with proper adapters, press the new lower ball joint into the knuckle until it is fully seated. The ball joint should be flush or slightly below the knuckle surface per manufacturer specifications. Ensure it presses in straight without cocking.
11. 11

    Install new upper ball joint
    Apply anti-seize to the new upper ball joint housing. Position the upper ball joint in the knuckle bore with the stud facing upward. Use the ball joint press to install the upper ball joint, ensuring it is driven in straight and fully seated. The joint should seat firmly with no movement. Some upper ball joints may have a snap ring or retaining clip that must be installed after pressing; verify your specific ball joint design and install any retainers as required.
12. 12

    Reinstall steering knuckle assembly
    Position the floor jack under the lower control arm again and raise it slightly to align the lower ball joint stud with the hole in the lower control arm. Maneuver the knuckle assembly back into position, threading the lower ball joint stud through the lower control arm. Install the lower castle nut hand-tight. Pivot the knuckle upward and align the upper ball joint stud with the upper control arm hole. Thread the upper castle nut onto the upper ball joint stud hand-tight.
13. 13

    Torque ball joint castle nuts
    Using a torque wrench, tighten the lower ball joint castle nut to the exact manufacturer specification per the factory service manual (do not rely on generic ranges; the 2007 Ram 3500 solid front axle uses a specific torque value that must be verified). Align the castle nut slots with the cotter pin hole; if needed, tighten further to the next slot alignment but do not back off. Install a new cotter pin and bend the ends to secure. Torque the upper ball joint castle nut to the exact manufacturer specification per the factory service manual (verify the specific 2007 Ram 3500 solid front axle value rather than using a generic range), align castle slots, install new cotter pin and bend ends to secure.
    ℹ️Consult factory service manual for exact torque specifications as they are not available in this database. Never loosen a castle nut to align cotter pin holes; only tighten to next alignment.
14. 14

    Reinstall brake and steering components
    Reinstall the brake rotor onto the hub. Position the brake caliper assembly over the rotor and align the caliper bracket with the mounting holes on the knuckle. Install and torque the caliper mounting bolts to specification. Reconnect the tie rod end to the steering knuckle, install the castle nut, torque to specification, and install a new cotter pin. Reconnect the ABS wheel speed sensor connector and secure all wire routing clips.
15. 15

    Install wheel and repeat for opposite side
    Reinstall the wheel and thread lug nuts by hand. Lower the vehicle until the tire just contacts the ground to prevent wheel rotation. Torque the lug nuts to the manufacturer specification for this vehicle (verify exact value in factory service manual; 2007 Ram 3500 typically requires approximately 145-160 ft-lbs depending on wheel configuration) in a star pattern. Repeat this entire procedure for the opposite side front wheel if both sides require ball joint replacement. Once both sides are complete, lower the vehicle fully and remove jack stands.

Reassembly

1. Torque all fasteners to factory specifications using a calibrated torque wrench
2. Install new cotter pins in all castle nuts and bend ends securely; never reuse old cotter pins
3. Verify all ABS sensor connectors and wire routing clips are properly secured
4. Check that brake caliper mounting bolts are tight and caliper moves freely on slides
5. Ensure tie rod end is properly seated and torqued with new cotter pin installed

Verification

• Start vehicle and turn steering wheel fully left and right while stationary to verify no binding or unusual noises from ball joints
• Test drive vehicle at low speed in a safe area and verify steering response is normal with no looseness or wandering
• Perform a visual inspection under the vehicle to confirm all fasteners are tight and no components are contacting
• Schedule a professional front-end alignment immediately after ball joint replacement, as suspension geometry will have changed
• After 50-100 miles of driving, re-torque all wheel lug nuts and re-inspect ball joint castle nuts and cotter pins for security

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