Front Suspension Rebuild

Complete rebuild of front suspension including upper and lower control arms, ball joints, tie rod ends, sway bar links, and strut assemblies on a 2007 Ram 3500 with 5.9L Cummins diesel.

Warnings

Tools required

Parts

• Upper control arms (pair) × 2 — Use OEM specification or equivalent
• Lower control arms (pair) × 2 — Use OEM specification or equivalent
• Upper ball joints (pair) × 2 — Use OEM specification or equivalent
• Lower ball joints (pair) × 2 — Use OEM specification or equivalent
• Outer tie rod ends (pair) × 2 — Use OEM specification or equivalent
• Inner tie rod ends (pair) × 2 — Use OEM specification or equivalent
• Sway bar end links (pair) × 2 — Use OEM specification or equivalent
• Strut assemblies with coil springs (pair) × 2 — Complete assembly recommended
• Strut top mount assemblies (pair) × 2 — Use OEM specification or equivalent
• Control arm bushings × 8 — Often included with control arms
• Ball joint pinch bolts × 4 — Replace if locknut style
• Cotter pins (assorted) × 8 — 3/16 and 1/4 inch
• Thread locker (medium strength) × 1 — Loctite 242 or equivalent

Preparation

1. Park vehicle on level surface and chock rear wheels securely
2. Disconnect negative battery cable to prevent accidental deployment of any electronic systems
3. Apply penetrating oil to all suspension fasteners and allow to soak for at least 30 minutes before beginning work
4. Raise front of vehicle and support on jack stands at frame rails behind lower control arm mounts
5. Remove front wheels and tires
6. Mark alignment cam positions on upper control arms with paint or scribe marks for reference
7. Measure and record tie rod lengths from inner to outer tie rod jam nut for rough alignment reference
8. Take photographs of brake line routing and ABS sensor wire locations

Procedure

1. 1

   Remove sway bar end links
   Support sway bar with jack or wire to prevent it from hanging. Remove nuts from both upper and lower sway bar end link studs on both sides. Use wrench on flats of ball stud to prevent spinning while loosening nuts. Remove end links from sway bar and lower control arm connections.
2. 2

   Disconnect outer tie rod ends from knuckles
   Remove cotter pins from outer tie rod end castle nuts. Loosen but do not remove castle nuts approximately 3 turns. Use tie rod end puller to separate taper from steering knuckle. Remove castle nuts and tie rod ends. Mark thread position on inner tie rod before loosening jam nut and unthreading outer tie rod end.
   ⚠Do not strike steering knuckle with hammer to separate tie rod taper as this can damage the knuckle or wheel bearing.
3. 3

   Remove brake caliper and rotor
   Remove brake caliper mounting bolts and support caliper with wire or bungee cord to prevent strain on brake hose. Do not let caliper hang by brake line. Remove brake rotor from hub. If rotor is stuck, use penetrating oil and brass hammer on rotor hat section. Disconnect ABS wheel speed sensor connector and carefully unclip sensor wire from routing tabs.
   ⚠Support brake caliper securely. Damage to brake hoses can cause complete brake failure.
4. 4

   Remove strut top mount nuts
   Locate the front shock absorbers. Remove the upper shock mounting nut/bolt at the frame bracket and the lower shock bolt at the axle bracket. Remove both left and right shock absorbers.
   Torque spec

   Strut Top Mount Nuts25 Nm (18 lb-ft)
5. 5

   Disconnect lower ball joint from knuckle
   Remove the lower ball joint nut where the lower ball joint stud passes through the axle housing yoke. Use a ball joint separator to break the taper between the lower ball joint stud and the axle yoke. Separate the steering knuckle from the axle housing.
   ⚠Ball joint may separate suddenly when taper breaks. Control steering knuckle to prevent injury.
   Torque spec

   Ball Joint Pinch Bolt50 Nm (37 lb-ft)
6. 6

   Disconnect upper ball joint from knuckle
   Remove cotter pin and castle nut from upper ball joint stud. Use ball joint separator to break taper between upper ball joint and steering knuckle. Remove steering knuckle assembly completely from vehicle. The knuckle, hub, and bearing assembly can now be set aside.
   ℹ️Steering knuckle assembly is heavy. Have assistant help support or use mechanic's wire to prevent dropping.
7. 7

   Remove strut assembly
   With upper mount nuts removed and ball joints disconnected, carefully lower strut assembly out from wheel well. Strut and coil spring assembly will come out as single unit. If installing new complete strut assemblies, proceed to control arm removal. If reusing springs, compress coil spring with spring compressor before disassembling strut components.
   ⚠️If disassembling strut, coil spring must be properly compressed with spring compressor before removing strut shaft nut. Failure to do so can cause spring to violently release causing severe injury or death.
8. 8

   Remove lower control arm
   Support the axle with a floor jack. Remove the radius arm-to-axle bolts and radius arm-to-frame-bracket bolts. Remove the track bar bolts at the axle and frame. These fasteners are large diameter and may require significant force. Inspect all mounting points for damage or excessive rust. Repeat for opposite side.
   ⚠Lower control arm bolts often seize in frame bushings. Heat may be required for removal. Ensure no brake lines or wiring are near heat source.
   Torque spec

   Lower Control Arm Bolts110 Nm (81 lb-ft)
9. 9

   Remove upper control arm
   This vehicle does not use upper control arms. Skip this step; caster/camber on the solid axle is adjusted via the ball joint alignment sleeve at the axle knuckle during reassembly.
   Torque spec

   Upper Control Arm Bolts90 Nm (66 lb-ft)
10. 10

    Install new upper control arms
    Position new upper control arms into frame brackets. Install upper control arm bolts finger tight. Position alignment cams to match reference marks made during disassembly. Do not torque bolts at this time as they must be torqued at ride height. Verify ball joint studs are properly oriented and grease fittings are accessible.
11. 11

    Install new lower control arms
    Position new lower control arms into frame brackets. Support with floor jack if needed for alignment. Install lower control arm bolts finger tight. Do not torque bolts at this time as they must be torqued at ride height. Verify ball joint orientation and sway bar link mounting position.
12. 12

    Install strut assemblies
    If using new complete strut assemblies, install directly. If reusing springs on new struts, transfer compressed spring and install new top mount bearing assembly. Lift strut assembly into position through lower control arm and into strut tower. Align top mount studs with holes in strut tower. Install and hand-tighten top mount nuts from engine compartment.
13. 13

    Reconnect steering knuckle to ball joints
    Seat the axle knuckle onto the lower ball joint stud. Install the lower ball joint retaining nut and torque to FSM specification. Connect the upper ball joint stud through the knuckle with the caster/camber alignment sleeve installed. Install the upper ball joint nut and torque to FSM specification, then install a new cotter pin where applicable.ecified.
    Torque spec

    Ball Joint Pinch Bolt50 Nm (37 lb-ft)
14. 14

    Install tie rod ends and sway bar links
    Thread the tie rod ends and drag link ends to previously recorded lengths and snug the adjuster sleeve clamps. Insert the tapered studs into the steering knuckle/pitman arm. Install the retaining nuts and torque to FSM specification, then install new cotter pins where applicable. Install new sway bar end links connecting the sway bar to the axle. Torque nuts to FSM specification.
    Torque spec

    Sway Bar End Link Nuts60 Nm (44 lb-ft)
15. 15

    Reinstall brake components and torque final fasteners
    Reinstall brake rotor and caliper. Reconnect ABS sensor and route wire through clips. Install wheels and torque lug nuts to FSM specification (approximately 145 lb-ft for this vehicle — verify exact value for your wheel type). Lower vehicle onto wheels so suspension is at ride height. Radius arm and track bar bolts MUST be final-torqued at ride height with vehicle weight on the suspension. Failure to do so can cause premature bushing failure. Torque strut top mount nuts to specification from engine compartment.
    ⚠Control arm bolts MUST be torqued at ride height with vehicle weight on suspension. Failure to do so will cause premature bushing failure.
    Torque spec

    Upper Control Arm Bolts90 Nm (66 lb-ft)

    Lower Control Arm Bolts110 Nm (81 lb-ft)

    Strut Top Mount Nuts25 Nm (18 lb-ft)

Reassembly

1. Reconnect negative battery cable
2. Pump brake pedal several times to restore brake pad contact with rotor before moving vehicle
3. Grease all suspension components with grease fittings using appropriate chassis grease
4. Check all fasteners for proper torque after test drive
5. Inspect for any fluid leaks around brake lines disturbed during service

Verification

• Test drive vehicle at low speed in safe area and verify no abnormal noises, vibrations, or handling issues
• Verify brake pedal is firm and brakes operate normally before road use
• Schedule professional wheel alignment immediately - vehicle will have severely incorrect alignment and tire wear will result
• After alignment, verify tie rod jam nuts are properly tightened
• Re-torque all suspension fasteners after 100 miles of driving
• Inspect for any loose components or abnormal tire wear after 500 miles

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