Control Arm Bushing - Front Lower

This procedure replaces the front lower control arm bushings on a 2007 Ram 3500 4WD with 5.9L Cummins diesel engine, requiring control arm removal and bushing press-out/press-in operations.

Warnings

Tools required

Parts

• Front lower control arm bushing set (2 bushings per arm) × 2 — Moog K200773 or equivalent
• Lower ball joint (if worn) × 1 — Inspect and replace as needed
• Anti-seize compound × 1 — Use copper or nickel-based

Preparation

1. Park vehicle on level concrete surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground (1/2 turn each)
4. Raise front of vehicle with floor jack at frame rail
5. Support vehicle on jack stands positioned at frame rails behind lower control arm mounts
6. Remove front wheels completely
7. Spray all control arm mounting bolts and ball joint hardware with penetrating oil
8. Allow vehicle to settle on jack stands and verify stability before working underneath

Procedure

1. 1

   Support lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the arm's weight. Raise jack just enough to contact the arm but not lift the vehicle. This prevents the arm from dropping suddenly when fasteners are removed.
2. 2

   Disconnect sway bar link
   Locate the sway bar end link connected to the lower control arm. Use a 19mm wrench to hold the stud and a 19mm socket to remove the nut. Disconnect the link from the control arm and swing it out of the way. If stud spins, use locking pliers on the stud end.
3. 3

   Remove shock absorber lower mount
   Locate the shock absorber lower mounting bolt that passes through the lower control arm. Use a 21mm socket and breaker bar to remove the bolt and nut. Support the shock if necessary and move it out of the work area.
   ⚠Do not allow shock absorber to hang by brake line - support with wire if needed
4. 4

   Separate ball joint from knuckle
   Remove the cotter pin from the lower ball joint castle nut. Use the correct socket for the lower ball joint castle nut (verify size in service manual) to loosen but leave it threaded on a few turns. Use a pickle fork or ball joint separator between the control arm and steering knuckle to break the taper. Once separated, remove the castle nut completely. Lower the floor jack slightly to allow the control arm to drop away from the knuckle.
   ⚠Keep castle nut partially threaded to prevent sudden separation - ball joint may pop loose with force
5. 5

   Remove front control arm pivot bolt
   Locate the front control arm pivot bolt that passes horizontally through the front bushing and frame mount. Verify the pivot bolt head size against the service manual before selecting a socket. Use a breaker bar and socket to remove the bolt completely. Note the orientation and any washers or spacers for reassembly.
6. 6

   Remove rear control arm mounting bolts
   Locate the rear control arm mounting bolts (there are typically two bolts at the rear bracket). Use appropriate sockets to remove these bolts completely. Lower the floor jack and remove the control arm from the vehicle. Inspect the ball joint for wear - if loose or torn boot, plan to replace it.
   ℹ️Rear mounting bolts may pass through frame brackets with limited clearance - wiggle arm while withdrawing
7. 7

   Press out old bushings
   Secure the control arm in a hydraulic press or use a portable bushing press kit. Position the bushing removal adapter to press the old bushing out of the control arm bore. Apply steady pressure until the bushing is completely expelled. Repeat for both front and rear bushings. Clean the bushing bores with a wire brush to remove rust and debris.
8. 8

   Install new bushings
   Apply a light coat of dish soap or bushing lubricant to the outer sleeve of the new bushings. Position the bushing squarely in the control arm bore with the correct orientation (voids or flats should align with arm movement axis). Use the hydraulic press with proper installation adapters to press the bushing in until fully seated and flush with the control arm housing. Ensure the bushing is not cocked or twisted during installation. Repeat for second bushing.
   ⚠Bushings must be aligned correctly before pressing - misalignment will damage the bushing and control arm
9. 9

   Reinstall control arm to frame
   Position the control arm back into the frame mounts. Insert the rear mounting bolts first and thread them in by hand but do not tighten. Insert the front pivot bolt through the front bushing and frame bracket, threading it by hand. Ensure all washers and spacers are in their original positions. Do not fully tighten any bolts yet.
10. 10

    Connect ball joint to knuckle
    Raise the control arm with the floor jack to align the ball joint stud with the hole in the steering knuckle. Insert the stud into the knuckle and thread on the castle nut. Tighten the castle nut to the manufacturer torque specification listed in the factory service manual for the 2007 Ram 3500 lower ball joint, then continue tightening as needed to align the cotter pin hole. Do not rely on a generic value; confirm the exact spec before final assembly. Align the castle nut slots with the stud hole and install a new cotter pin. Bend the cotter pin ends to secure.
11. 11

    Reinstall shock absorber and sway bar
    Reconnect the shock absorber lower mounting bolt through the control arm and tighten to manufacturer specification. Reconnect the sway bar end link to the control arm and tighten the nut while holding the stud to prevent spinning. Use thread locker if specified by manufacturer.
12. 12

    Torque all fasteners at ride height
    With the control arm reconnected, raise the floor jack under the control arm to simulate normal ride height (suspension at approximately mid-travel). In this loaded position, torque all control arm mounting bolts to manufacturer specifications in the following sequence: rear mounting bolts first, then front pivot bolt. This prevents bushing bind. Remove the supporting floor jack.
    ⚠Control arm bolts must be torqued at ride height to prevent premature bushing failure - do not torque with suspension hanging
13. 13

    Repeat for opposite side
    If replacing bushings on both sides, repeat steps 1-12 for the opposite control arm. It is recommended to replace bushings on both sides simultaneously to maintain balanced handling characteristics.

Reassembly

1. Reinstall wheels and hand-tighten lug nuts in a star pattern
2. Lower vehicle to ground and remove jack stands
3. Torque wheel lug nuts to 135 ft-lbs in a star pattern
4. Test drive vehicle at low speed in safe area to verify no unusual noises or handling issues
5. All control arm mounting bolts should be checked for proper torque as vehicle weight settles

Verification

• Verify all fasteners are tight and properly torqued at ride height
• Check that ball joint castle nut has cotter pin installed and secured
• Inspect for any interference between control arm and frame or other components through full suspension travel
• Schedule professional wheel alignment immediately - front suspension geometry has been altered
• After 50-100 miles, re-check all fastener torque values
• Monitor for any clunking noises or irregular tire wear indicating alignment issues

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