Control Arm Bushing - Front Upper

This procedure covers the replacement of the front upper control arm bushings on a 2007 Ram 3500 with the 5.9L Cummins diesel engine and 4WD.

Warnings

Tools required

Parts

• Front upper control arm bushing kit (left and/or right) × 1 — Use OEM specification or Moog K8607
• Upper ball joint castle nut (if worn or damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground (21mm)
4. Raise front of vehicle and support securely on jack stands at frame rails
5. Remove front wheel on side being serviced
6. Spray all control arm bolts and ball joint nut with penetrating oil and allow to soak for 15-20 minutes
7. Inspect upper ball joint condition - if ball joint requires replacement, plan accordingly as it may need to be pressed out with the bushing

Procedure

1. 1

   Support the lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the weight of the knuckle and suspension. Raise the jack just enough to take the load off the upper ball joint. This prevents the knuckle from dropping when the upper control arm is disconnected.
2. 2

   Remove upper ball joint cotter pin and nut
   Remove the cotter pin from the upper ball joint castle nut using pliers or wire cutters. Using the correct size socket (verify against manufacturer documentation), remove the castle nut from the ball joint stud. Do not fully remove support from floor jack under lower control arm yet.
   ⚠Keep the floor jack in place under the lower control arm to prevent the knuckle from dropping when the ball joint separates.
3. 3

   Separate upper ball joint from knuckle
   Use a ball joint separator tool or pickle fork to separate the upper ball joint stud from the steering knuckle. Position the tool between the control arm and knuckle, then strike with a hammer or use the threaded separator to apply pressure. Once separated, carefully lower the floor jack to allow the knuckle to drop away from the upper control arm.
   ⚠The knuckle will drop when the ball joint releases. Control the descent with the floor jack to prevent damage to brake lines or CV axle.
4. 4

   Remove front control arm mounting bolt
   Locate the front upper control arm mounting bolt at the frame bracket. This bolt runs horizontally through the front bushing. Using an 18mm socket and wrench, remove the nut from the backside while holding the bolt head. Remove the bolt and note any alignment shims or washers for reinstallation in the same position.
5. 5

   Remove rear control arm mounting bolt
   Locate the rear upper control arm mounting bolt at the frame bracket. Using an 18mm socket and wrench, remove the nut from the backside while holding the bolt head. Remove the bolt and note any alignment shims or washers for reinstallation. The control arm can now be removed from the vehicle.
6. 6

   Clean control arm and inspect
   With the control arm removed, use a wire brush to clean the bushing mounting areas and the entire control arm. Inspect the control arm for cracks, bends, or excessive corrosion. Check the ball joint for play or torn boots - replace if necessary. Inspect the frame mounting brackets for damage or excessive wear.
7. 7

   Press out old bushings
   Using a hydraulic press and appropriately sized bushing removal tools or a control arm bushing service kit, press out the old bushings from both the front and rear mounting points of the control arm. Note the orientation of the bushings before removal. Apply steady pressure and ensure the bushing is being pressed straight out to avoid damaging the control arm bore.
   ⚠Ensure proper alignment of press tools to prevent damage to control arm mounting bores. Uneven pressure can distort the metal.
8. 8

   Clean bushing bores
   After old bushings are removed, clean the bushing bores in the control arm thoroughly with a wire brush and clean cloth. Remove all rust, old rubber, and debris. Inspect the bores for damage or excessive wear that would prevent proper bushing seating.
9. 9

   Press in new bushings
   Apply a light coat of dish soap or bushing installation lubricant to the outside of the new bushings and the control arm bores. Position the new bushings in the correct orientation (noting any offset or directional indicators on the bushing). Using the hydraulic press and proper sized installation tools, press the new bushings into the control arm until fully seated and flush with the control arm surface.
   ℹ️Some bushings have a specific orientation or void pattern. Verify correct orientation before pressing to ensure proper suspension geometry.
10. 10

    Install control arm to frame bracket
    Position the control arm back into the frame mounting brackets. Install the front mounting bolt through the bushing and bracket, ensuring any alignment shims or washers are reinstalled in their original positions. Start the nut on the backside but do not fully tighten yet. Repeat for the rear mounting bolt. Leave both bolts loose enough to allow some movement.
11. 11

    Connect upper ball joint to knuckle
    Using the floor jack, raise the steering knuckle up to meet the upper ball joint stud. Align the stud with the hole in the knuckle and push the knuckle onto the stud. Install the castle nut and tighten to the manufacturer-specified torque (verify exact value against service documentation for this specific axle). Align the castle nut slots with the cotter pin hole and install a new cotter pin. Bend the cotter pin ends to secure.
12. 12

    Torque control arm mounting bolts at ride height
    With the ball joint connected, use the floor jack under the lower control arm to raise the suspension to normal ride height (simulate vehicle weight on suspension). With suspension at ride height, torque the front and rear control arm mounting bolts to the manufacturer-specified torque (verify exact values against service documentation for this specific vehicle). Torquing at ride height is critical to prevent premature bushing failure.
    ⚠Control arm mounting bolts MUST be torqued with suspension at ride height. Torquing with suspension hanging can cause bushing bind and premature failure.
13. 13

    Reinstall wheel and lower vehicle
    Remove the floor jack from under the lower control arm. Reinstall the front wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle to the ground and torque the wheel lug nuts to the manufacturer-specified torque (verify exact value for this application) in a star pattern.

Reassembly

1. If both sides were serviced, repeat procedure for opposite side
2. Double-check all fasteners are properly torqued
3. Verify cotter pin is properly installed and secured on ball joint castle nut

Verification

• Test drive vehicle at low speed and verify no unusual noises from front suspension
• Check for proper steering response and alignment
• Inspect for any fluid leaks around disturbed components
• Schedule a front-end alignment within 50 miles of completion as bushing replacement affects suspension geometry

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