Knuckle/Spindle - Front

This procedure covers the removal and replacement of the front steering knuckle/spindle assembly on a 2007 Ram 3500 with 5.9L Cummins diesel engine and 4WD.

Warnings

Tools required

Parts

• Front steering knuckle/spindle assembly × 1 — Use OEM specification
• Wheel bearing and hub assembly (if integrated) × 1 — Use OEM specification
• Upper ball joint (if not included with knuckle) × 1 — Use OEM specification
• Lower ball joint (if not included with knuckle) × 1 — Use OEM specification
• Tie rod end (inspect and replace if worn) × 1 — Use OEM specification
• Axle nut × 1 — Use OEM specification
• Cotter pins (various sizes) × 4 — Assorted pack
• Brake cleaner × 1 — Aerosol can
• Anti-seize compound × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on the ground (do not remove)
4. Loosen front axle nut while vehicle is on the ground (requires significant torque)
5. Raise front of vehicle and support on jack stands at frame rails
6. Remove front wheel completely
7. Apply penetrating oil to ball joint castellated nuts, tie rod end nut, and all suspension fasteners; allow to soak 15-30 minutes if components are rusty

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the two brake caliper mounting bolts and carefully lift the caliper off the rotor. Support the caliper with a wire hanger or bungee cord to avoid stressing the brake hose - do not let it hang by the hose. Remove the brake rotor by pulling it straight off the hub studs. If stuck, use penetrating oil and light taps with a hammer on the rotor face.
2. 2

   Disconnect ABS wheel speed sensor
   If equipped with a front wheel speed sensor, locate the ABS sensor and connector. Disconnect the electrical connector by pressing the release tab. Remove the sensor mounting bolt and carefully extract the sensor. Clean the sensor bore if debris is present. Verify sensor type and location in the service manual.
3. 3

   Remove axle shaft nut
   Remove the front axle shaft nut completely (should already be loosened from preparation). Verify the hub/axle retention type in the service manual. This platform may use a spindle nut arrangement rather than a single high-torque staked axle nut; torque values and retention (cotter pin, lock washer, or stake) must be confirmed for the specific hub design. Set the nut aside as most manufacturers recommend replacing with a new nut.
4. 4

   Disconnect tie rod end
   Remove the cotter pin from the tie rod end castle nut. Loosen but do not completely remove the castle nut (leave it threaded a few turns). Use a tie rod end puller or pickle fork to separate the tie rod end from the knuckle steering arm. Once separated, remove the castle nut completely. Be prepared for sudden release when the taper breaks free.
   ⚠Using a pickle fork will likely damage the tie rod end boot. Have a replacement tie rod end available if using this method.
5. 5

   Separate upper ball joint
   Remove the cotter pin from the upper ball joint castle nut. Loosen but do not completely remove the castle nut (leave it threaded a few turns for safety). Use a ball joint separator tool to break the taper between the ball joint stud and the knuckle. Once separated, remove the castle nut completely. Support the knuckle as it will become loose.
   ⚠The knuckle and hub assembly is heavy and may drop suddenly when the upper ball joint separates. Maintain control of the assembly.
6. 6

   Separate lower ball joint
   Remove the cotter pin from the lower ball joint castle nut. Loosen but do not completely remove the castle nut. Use a ball joint separator or pickle fork to break the taper between the lower ball joint stud and the knuckle. Once the taper is broken, remove the castle nut completely while supporting the knuckle assembly.
7. 7

   Remove knuckle from axle shaft
   With both ball joints and tie rod disconnected, carefully separate the knuckle from the axle housing tube. Remove the outer axle shaft as required. If the spindle or hub is seized, use appropriate pullers to separate the components. Completely remove the knuckle assembly from the vehicle. The inner axle shaft may slide within the axle tube. The spindle and axle shaft are part of a solid front axle assembly. Support the components as they are separated.
   ⚠The CV axle shaft may try to slide out of the differential. Have a drain pan ready in case differential fluid leaks. Insert a plug or rag into the differential opening if the axle shaft pulls completely out.
8. 8

   Inspect and prepare mounting points
   Clean all ball joint tapers on the control arms using a wire brush and brake cleaner. Inspect the ball joint boots for tears or damage and replace ball joints if necessary. Clean the tie rod end taper on the knuckle steering arm. Use a thread chaser to clean all threaded holes. Inspect the CV axle shaft splines for damage or excessive wear.
9. 9

   Prepare new knuckle assembly
   Unpack the new knuckle assembly and verify it matches the old unit. If the wheel bearing/hub is separate, install it into the new knuckle according to manufacturer specifications (typically pressed in). Install the ABS sensor into the new knuckle if it was removed separately. Apply a thin coat of anti-seize to the spindle/axle shaft splines and mating surfaces as appropriate.
10. 10

    Install knuckle onto axle shaft
    Carefully position the new knuckle assembly onto the ball joint studs at the axle housing tube end. Install the outer axle shaft and spindle/hub as required, ensuring the splines engage properly. If resistance is encountered, check for proper alignment and clean splines.
11. 11

    Connect lower ball joint
    Align the lower ball joint stud with the hole in the bottom of the knuckle. Insert the stud through the knuckle and thread on the castle nut. Tighten the lower ball joint nut to the factory-specified torque (consult service manual — Dana 60 lower ball joint torque and any adjusting/jam nut sequence differs from generic values). 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

    Connect upper ball joint
    Align the upper ball joint stud with the hole in the top of the knuckle. You may need to use a pry bar to position the knuckle properly. Insert the stud through the knuckle and thread on the castle nut. Tighten the upper ball joint nut to the factory-specified torque and follow the correct upper ball joint adjusting/sequence procedure (consult service manual — generic values do not apply to this axle). Align castle nut slots with the cotter pin hole and install a new cotter pin. Bend the cotter pin ends to secure.
13. 13

    Connect tie rod end
    Insert the tie rod end stud into the steering arm on the knuckle. Thread on the castle nut and tighten to specification (typically 45-65 ft-lbs). Align the castle nut slots with the cotter pin hole. If slots don't align, tighten further (do not loosen). Install a new cotter pin and bend the ends to secure.
14. 14

    Install axle nut and ABS sensor
    Install the new axle shaft nut and tighten snug but not to final torque yet (will be torqued with wheel on ground). Reconnect the ABS wheel speed sensor electrical connector. Ensure the sensor wire is properly routed away from moving suspension components and rotating parts.
15. 15

    Reinstall brake components
    Clean the hub face with brake cleaner and remove any rust or debris. Reinstall the brake rotor onto the hub studs. Position the brake caliper over the rotor and install the caliper mounting bolts. Tighten caliper bolts to specification (typically 24-38 ft-lbs). Pump the brake pedal several times to reseat the caliper pistons before moving the vehicle.

Reassembly

1. Install the wheel and hand-tighten all lug nuts
2. Lower the vehicle until the tire just contacts the ground (weight still supported by jack stands)
3. Torque the front axle nut to specification (typically 250-275 ft-lbs for this vehicle - verify in service manual)
4. Torque wheel lug nuts in a star pattern to 135 ft-lbs
5. Completely lower the vehicle to the ground
6. Remove jack stands and lower jack completely
7. Double-check that all fasteners are tight and all cotter pins are properly installed

Verification

• Start the vehicle and verify no ABS warning lights are illuminated on the dash
• Turn the steering wheel fully left and right to ensure full range of motion without binding or unusual noises
• Test drive the vehicle at low speed in a safe area, checking for vibrations, pulling, or unusual noises
• Perform a visual inspection under the vehicle after test drive to check for any fluid leaks from the differential
• Schedule a professional wheel alignment immediately - knuckle replacement will affect camber, caster, and toe settings
• After 50-100 miles, re-torque the axle nut and wheel lug nuts to specification

More procedures for this vehicle