Leaf Spring Bushing

This procedure covers the replacement of worn leaf spring bushings on the rear suspension of a 2007 Ram 3500 4WD with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Leaf spring bushing kit (front or rear) × 1 — Use OEM specification or Moog K200162
• U-bolt kit (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks in front of both front wheels
3. Spray all leaf spring mounting bolts, U-bolts, and shackle bolts with penetrating oil and allow to soak
4. Loosen rear wheel lug nuts while vehicle is on the ground (do not remove)
5. Raise rear of vehicle and support frame rails with jack stands rated for at least 3 tons each
6. Remove rear wheels completely

Procedure

1. 1

   Support the rear axle
   This procedure covers the replacement of worn rear leaf spring bushings on a 2007 Ram 3500 4WD with the 5.9L Cummins diesel engine. Note: references to 'front bushing' refer to the front eye of the rear leaf spring, not the front axle (this 4WD uses coil springs up front). Place a floor jack under the rear axle housing near the leaf spring you'll be working on. Raise jack just enough to make light contact and support the axle weight. This relieves tension on the leaf spring mounting hardware and prevents the axle from dropping when hardware is removed.
2. 2

   Remove U-bolts
   Using the correct socket for your hardware (verify size on the vehicle; often 21mm on this heavy-duty application), remove the four nuts securing the U-bolts that clamp the leaf spring to the axle. Remove the U-bolts and the lower spring plate. Note the orientation of the plate for reassembly.
3. 3

   Remove rear shackle bolts (if replacing rear bushing)
   If replacing the rear bushing, use a 21mm socket to remove the upper and lower shackle bolts connecting the rear of the leaf spring to the frame-mounted shackle bracket. The shackle will remain attached to the spring. Support the spring end as you remove the second bolt to prevent it from dropping.
4. 4

   Remove front spring mounting bolt (if replacing front bushing)
   If replacing the front bushing, use a 21mm socket and breaker bar to remove the large bolt that passes through the front spring eye and frame bracket. This bolt may require significant force to remove due to corrosion. You may need to use a pry bar to separate the spring eye from the bracket once the bolt is removed.
5. 5

   Lower the leaf spring
   Carefully lower the floor jack supporting the axle. The spring will separate from the axle. If working on the front bushing only, rotate the spring downward from the front mount. If working on the rear bushing, the spring will come free entirely. Have an assistant help support the spring weight.
6. 6

   Remove old bushings
   Using a bushing press kit or hydraulic press, press out the old bushing from the spring eye. The bushing consists of an outer metal sleeve bonded to a rubber bushing with an inner metal sleeve. Apply pressure evenly to avoid damaging the spring eye. If the bushing is severely deteriorated, you may need to cut away rubber and collapse the outer sleeve with a chisel to remove it.
7. 7

   Clean the spring eye
   Use a wire brush to thoroughly clean the inside of the spring eye, removing all rust, old rubber residue, and debris. The bore must be clean for the new bushing to seat properly. Inspect the spring eye for cracks or deformation.
8. 8

   Install new bushing
   Apply a light coat of dish soap or bushing installation lubricant to the outer sleeve of the new bushing (never use petroleum-based lubricants as they damage rubber). Position the bushing centered in the spring eye. Using the bushing press or hydraulic press, carefully press the new bushing into the spring eye until it is fully seated and flush on both sides. Ensure the bushing is not cocked or misaligned during installation.
9. 9

   Reinstall the leaf spring
   Lift the spring back into position. If you removed the front mount bolt, align the spring eye with the frame bracket and insert the bolt finger-tight. If you removed the shackle, align the shackle with the frame bracket and install both shackle bolts finger-tight. Raise the axle with the floor jack to align the spring with the axle perch.
10. 10

    Install U-bolts and spring plate
    Position the lower spring plate on the bottom of the spring, ensuring proper orientation. Install the U-bolts through the plate and up around the axle and spring. Thread all four nuts onto the U-bolts and tighten in a criss-cross pattern gradually until the spring is firmly clamped to the axle. Do not fully torque at this stage.
11. 11

    Torque all fasteners
    With the vehicle weight now on the suspension (axle supported by jack at ride height), torque all fasteners. Since factory torque specifications are not available in the database, consult a factory service manual for exact values. Consult the factory service manual for exact values for this specific truck, as leaf spring and U-bolt torque specs vary by U-bolt diameter on the 3500-series HD. Do not rely on generic values; verify front spring eye bolt, shackle bolt, and U-bolt nut torque against manufacturer documentation before final tightening. All torquing should be performed with the suspension at normal ride height, not fully extended.
12. 12

    Reinstall wheels and lower vehicle
    Reinstall the rear wheels and hand-tighten lug nuts. Remove jack stands and carefully lower the vehicle to the ground. Torque wheel lug nuts to factory specification (verify exact value against manufacturer documentation for this specific truck, as SRW and DRW configurations differ) in a star pattern.

Reassembly

1. All suspension fasteners must be torqued with the vehicle at normal ride height, not with suspension hanging or fully compressed
2. Inspect all rubber bushings in the suspension system while performing this repair
3. If U-bolts show signs of thread damage or severe corrosion, replace them as a set
4. Apply anti-seize compound to bolt threads before installation to ease future removal

Verification

• Verify all fasteners are properly torqued and no hardware was left loose
• Test drive the vehicle at low speed and listen for any unusual noises from the rear suspension
• Check for proper ride height on both sides of the vehicle
• After 50-100 miles, re-torque all U-bolt nuts and suspension bolts as bushings may settle
• Inspect for any signs of bushing movement or improper seating after test drive

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