CV Axle - Front

This procedure covers the removal and replacement of the front CV axle shaft assembly on a 2007 Ram 3500 4WD with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• CV axle shaft assembly × 1 — Use OEM or equivalent heavy-duty aftermarket for diesel application
• Axle hub nut × 1 — One-time use, replace during installation
• Differential seal (if damaged) × 1 — Replace if leaking or damaged during removal

Fluids

• 75W-90 synthetic gear oil — 1 qt

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
4. Loosen but do not remove the 36mm axle hub nut while vehicle is on ground (may require breaker bar)
5. Raise front of vehicle and support securely on jack stands at frame rails
6. Remove front wheel and tire assembly
7. Place drain pan under differential to catch gear oil spillage

Procedure

1. 1

   Remove axle hub nut
   Remove the axle hub/spindle nut from the end of the axle shaft (verify size and torque with the service manual). If the axle spins, have an assistant apply the brakes to hold it.
2. 2

   Disconnect upper ball joint
   Remove the front hub/unit bearing retaining bolts and the hub assembly from the knuckle to gain access to the axle shaft; ball joint separation is not required for axle shaft removal on this solid front axle.
3. 3

   Disconnect lower ball joint
   Remove the lower ball joint nut from the steering knuckle. Use the ball joint separator to disconnect the lower ball joint from the knuckle. The knuckle and hub assembly should now be free to move outward.
4. 4

   Remove outer CV joint from hub
   Pull the steering knuckle and hub assembly outward away from the vehicle. The outer CV joint splined shaft should slide out of the hub bearing. If stuck, tap gently on the end of the axle shaft with a brass punch and hammer. Support the axle to prevent it from dropping.
5. 5

   Remove inner CV joint from differential
   Slide the inner axle shaft out of the axle tube; the shaft is retained differently than an IFS C-clip design. Some fluid loss from the tube may occur on the long side—have a drain pan ready.
6. 6

   Inspect differential seal
   Inspect the differential output seal for damage or leakage. Clean the seal area with a wire brush. If the seal shows signs of wear, leaking, or damage, replace it now before installing the new axle.
7. 7

   Prepare new CV axle
   Compare the new CV axle to the old unit to ensure proper length and configuration. Inspect both CV boots for damage and ensure clamps are properly secured. Clean any protective coating from the splined surfaces if present.
8. 8

   Install inner CV joint into differential
   Align the inner CV joint splines with the differential side gear. Push the axle firmly into the differential until the C-clip engages with a distinct click or snap. Tug on the axle to verify it is locked in place and will not pull out.
9. 9

   Install outer CV joint into hub
   Guide the outer CV joint splined shaft into the hub bearing. Push the knuckle assembly inward toward the vehicle while aligning the splines. The shaft should slide completely through the hub bearing. Clean the axle shaft threads before proceeding.
10. 10

    Reconnect ball joints
    Position the steering knuckle to align the upper and lower ball joint studs with their respective mounting points. Install the upper ball joint into the knuckle first, then the lower. Install new ball joint nuts and tighten to manufacturer specification. Install cotter pins if equipped.
11. 11

    Install new axle hub nut
    Thread the new 36mm axle hub nut onto the axle shaft by hand. Do not fully torque at this time. The nut should thread smoothly without cross-threading.
12. 12

    Reinstall wheel and lower vehicle
    Install the wheel and tire assembly. Thread lug nuts by hand and snug with a socket. Lower the vehicle until the tire just contacts the ground but weight is still on the jack stands.
13. 13

    Torque axle hub nut
    With the tire on the ground to prevent rotation, torque the axle hub/spindle nut to the manufacturer's specification (verify exact value with the service manual for this vehicle). Have an assistant apply brakes if needed to prevent rotation. Stake or install cotter pin if equipped.
14. 14

    Final torque and lower vehicle
    Fully lower the vehicle to the ground. Torque all wheel lug nuts to specification in a star pattern. Check front differential fluid level and top off with the manufacturer-specified gear oil grade for this axle (verify grade and any friction modifier requirement in the service manual).

Reassembly

1. Ensure all ball joint nuts are properly torqued and cotter pins installed
2. Verify axle hub nut is fully torqued and secured
3. Check that CV axle inner joint is fully seated in differential with C-clip engaged
4. Top off front differential fluid to proper level through fill plug

Verification

• Start engine and turn steering wheel full lock left and right while stationary, listening for any clicking or popping from CV joints
• Test drive vehicle at low speed, making several turns in both directions to verify smooth operation
• Check for any vibration during acceleration that would indicate improper installation
• Inspect for any differential fluid leaks around the inner CV joint area
• Re-check front differential fluid level after test drive and top off if needed

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