Coil Springs - Front Pair

This procedure covers the removal and replacement of both front coil springs on a 2007 Ram 3500 with the 5.9L Cummins diesel engine and 4WD, requiring spring compressor tools and suspension disassembly.

Warnings

Tools required

Parts

• Front coil spring (left) × 1 — Heavy-duty coil spring for 4WD model
• Front coil spring (right) × 1 — Heavy-duty coil spring for 4WD model
• Shock absorber lower mounting hardware × 1 — Use OEM specification if corroded
• Upper ball joint nut × 2 — Use OEM specification, one-time use
• Lower ball joint nut × 2 — Use OEM specification if damaged

Preparation

1. Park vehicle on level, solid ground and engage parking brake. Chock rear wheels securely.
2. Apply penetrating oil to front suspension fasteners (upper and lower ball joint nuts, shock absorber mounting bolts, track bar bolts) and allow to soak for at least 30 minutes.
3. Loosen front wheel lug nuts while vehicle is on the ground, but do not remove.
4. Raise front of vehicle using a floor jack at the front axle differential housing until tires are off the ground.
5. Place jack stands under the frame rails behind the front suspension, rated for at least 3 tons each. Lower vehicle onto stands.
6. Remove front wheels completely and set aside.
7. Visually inspect spring compressor tools to ensure they are heavy-duty rated and in good condition with no cracks or damaged threads.

Procedure

1. 1

   Support the front axle
   Position a floor jack under the front axle differential housing with a block of wood to distribute the load. Raise the jack just enough to contact the axle but not lift it. This will support the axle when suspension components are disconnected and allow controlled lowering of the axle to access the coil springs.
2. 2

   Disconnect the track bar
   Locate the track bar; note that on this vehicle it connects to the axle on the driver side and to the frame on the passenger side. Remove the axle-end mounting bolt. Remove the track bar mounting bolt at the axle end using a wrench and socket. You may need to use a breaker bar due to tight torque. Swing the track bar up and away from the axle, securing it with wire or zip ties to prevent interference.
3. 3

   Disconnect the front sway bar links
   Remove the sway bar end link bolts at both the driver and passenger sides where they connect to the axle. Note the fastener size before starting and use the correct size socket/wrench. You may need to hold the stud with a wrench while loosening the nut. Allow the sway bar to hang free.
4. 4

   Disconnect the lower shock absorber mounts
   Locate the lower shock absorber mounting bolts on both sides of the vehicle where the shocks attach to the axle mounting brackets. Remove these bolts completely using a socket and breaker bar. The shocks will now be free at the bottom and can hang from their upper mounts.
5. 5

   Disconnect the drag link at the steering knuckle
   On the passenger side, locate the drag link connection at the steering knuckle. Remove the cotter pin and castle nut from the drag link end. Use a ball joint separator or pickle fork to separate the drag link from the knuckle. Secure the drag link up and out of the way to prevent damage.
   ⚠Do not turn the steering wheel once the drag link is disconnected, as this can damage the steering components or make reassembly difficult.
6. 6

   Lower the axle to access the first coil spring
   Slowly and carefully lower the floor jack supporting the front axle. As the axle drops, the coil springs will begin to extend. Lower the axle approximately 4-6 inches until you can see the coil spring clearly and access it from the side. Do not lower too far yet. Start with the driver side spring.
7. 7

   Install spring compressor on driver side spring
   Install the coil spring compressor tools on the driver side spring, following the compressor manufacturer's instructions. Install compressor hooks or arms on opposite sides of the spring (180 degrees apart) and at least 2-3 coils from each end of the spring. Ensure the compressor tools are seated properly in the coil valleys and are secure.
   ⚠️Ensure spring compressor tools are properly rated for heavy-duty truck springs. Light-duty compressors can fail catastrophically.
8. 8

   Compress the driver side spring
   Slowly and evenly tighten the spring compressor tools, alternating between sides to compress the spring evenly. Compress the spring until it is loose in its seat and no longer under load between the upper spring seat and lower spring seat. You should be able to wiggle the spring slightly when properly compressed. Continue to lower the axle slightly with the jack if needed to create clearance.
9. 9

   Remove the driver side coil spring
   With the spring fully compressed and the axle lowered sufficiently, carefully remove the compressed coil spring assembly from between the upper spring seat (on the frame) and lower spring seat (on the axle). Maneuver the spring out through the suspension components. Keep the spring compressors installed and tight.
10. 10

    Install new driver side coil spring
    Install the spring compressors on the new driver side coil spring and compress it to approximately the same length as the old spring was when removed. Note the orientation of the spring end coils (top and bottom may be different). Install the compressed new spring between the upper and lower spring seats, ensuring the spring ends are properly seated in their locating tabs or pockets. Verify correct positioning.
11. 11

    Release driver side spring tension
    Slowly raise the floor jack to lift the axle back up, which will begin to load the new spring. As the axle rises, slowly and evenly loosen the spring compressor tools, alternating sides. Continue raising the axle and releasing the compressors until the spring is fully seated and bearing the suspension load. Remove the compressor tools completely once the spring is fully loaded and seated.
12. 12

    Repeat spring replacement for passenger side
    Repeat steps 6 through 11 for the passenger side coil spring. Lower the axle using the floor jack, install spring compressors on the passenger side spring, compress evenly, remove the old spring, install and compress the new spring, position it correctly, then raise the axle and release the compressors to seat the new spring.
13. 13

    Reconnect the drag link
    With both springs replaced and the axle raised to normal ride height, reconnect the drag link to the passenger side steering knuckle. Install the castle nut and torque to the factory service manual specification, then install a new cotter pin (advance to the next slot if needed to align). Ensure the connection is tight and the steering moves freely.
14. 14

    Reconnect suspension components
    Reinstall the lower shock absorber mounting bolts on both sides and tighten securely using a torque wrench if specifications are available. Reconnect the sway bar end links on both sides and tighten the nuts. Reattach the track bar to the axle bracket and install the mounting bolt, tightening securely with a torque wrench.
15. 15

    Reinstall wheels and lower vehicle
    Reinstall both front wheels and hand-tighten the lug nuts in a star pattern. Raise the vehicle slightly with the floor jack to remove the jack stands from under the frame. Carefully lower the vehicle to the ground. With the vehicle on the ground and full weight on the suspension, torque the wheel lug nuts to the factory service manual specification (verify exact value for your wheel configuration) in a star pattern.

Reassembly

1. Verify all suspension fasteners are properly tightened, including track bar, sway bar links, shock absorber mounts, and drag link connection.
2. Check that the coil springs are properly seated in both upper and lower spring seats with no signs of binding or misalignment.
3. Verify steering operates smoothly through full left and right travel without binding.
4. Double-check that all spring compressor tools have been removed from both springs.

Verification

• Perform a visual inspection of both front coil springs to ensure they are fully seated and properly positioned in their spring seats.
• Bounce the front end of the vehicle several times and listen for any unusual noises indicating loose or improperly installed components.
• Check ride height on both sides to ensure it is even and matches the opposite side.
• Test drive the vehicle at low speed in a safe area to verify normal handling and listen for any suspension noises.
• Have the vehicle professionally aligned immediately after spring replacement, as ride height and suspension geometry have changed.
• After the first 50-100 miles, re-torque all suspension fasteners and verify wheel lug nut torque.

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