Leaf Spring

This procedure covers the removal and replacement of rear leaf springs on a 2007 Ram 3500 4WD with 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Rear leaf spring assembly × 1 — Use OEM specification for correct load rating
• Leaf spring shackle bushings × 2 — Use OEM specification
• Leaf spring eye bushings × 2 — Use OEM specification
• U-bolt set × 1 — Use OEM specification
• U-bolt plate × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks in front of front wheels
3. Apply penetrating oil to all leaf spring mounting bolts, U-bolts, and shackle hardware. Allow to soak for at least 30 minutes
4. Loosen rear wheel lug nuts while vehicle is on ground
5. Raise rear of vehicle and support frame rails with jack stands rated for vehicle weight
6. Remove rear wheel on side being serviced
7. Position transmission jack or adjustable stand under rear axle housing to support weight

Procedure

1. 1

   Support the rear axle
   Position the transmission jack or adjustable stand directly under the rear axle housing near the leaf spring being replaced. Raise the jack until it just contacts the axle but does not lift it. The axle needs to be supported but allow slight downward movement during disassembly.
2. 2

   Remove shock absorber lower mount
   Remove the lower shock absorber mounting bolt using an 18mm socket. Allow the shock absorber to hang freely or secure it with wire to the frame to keep it out of the way.
3. 3

   Remove U-bolts
   Using the correct size socket (verify against OEM specification — these heavy-duty U-bolt nuts are typically larger than standard hardware), remove the four U-bolt nuts securing the leaf spring to the axle. Remove the U-bolts and save the U-bolt plate. Note the orientation of the plate for reinstallation. If U-bolts are corroded or damaged, replace them.
4. 4

   Remove rear shackle bolts
   Using a 3/4 inch socket, remove the two bolts securing the rear spring shackle to the frame bracket and to the rear spring eye. The shackle may need to be pried free if bushings are deteriorated. Note the orientation of any washers or spacers for reassembly.
5. 5

   Remove front spring eye bolt
   Using a 3/4 inch socket, remove the bolt securing the front spring eye to the front hanger bracket. This bolt typically passes through from the inside of the frame. Support the leaf spring as this bolt is removed to prevent it from falling.
6. 6

   Remove leaf spring assembly
   Carefully lower the transmission jack slightly to allow clearance for spring removal. Maneuver the leaf spring assembly out from under the vehicle. You may need to rotate or angle the spring to clear the axle and frame components. Inspect all mounting points on the frame for damage or excessive rust.
7. 7

   Inspect and prepare mounting points
   Clean all mounting surfaces on the frame hangers and axle saddle using a wire brush. Remove rust, old paint, and debris. Inspect frame hangers for cracks, excessive rust, or damage. If bushings are being replaced separately from the spring, press or drive out old bushings from the spring eyes now.
8. 8

   Install new leaf spring front eye
   Position the new leaf spring assembly with the front eye aligned with the front hanger bracket. Insert the front eye bolt from the inside of the frame through the hanger and spring eye. Install the nut but do not fully tighten yet - leave it finger tight plus one turn to allow movement during axle positioning.
9. 9

   Install rear shackle
   Connect the rear spring eye to the frame using the shackle assembly and bolts. Install both shackle bolts but do not fully tighten - leave them finger tight plus one turn. The spring needs to pivot freely to align with the axle.
10. 10

    Position axle on spring
    Using the transmission jack, raise the axle until the spring center pin locates properly in the axle saddle hole. Ensure the spring is centered on the axle pad with equal overhang on both sides. Ensure the axle pinion angle matches the OEM factory specification; on leaf-sprung solid axles the pinion is generally set slightly nose-down at static ride height to allow for rotation under load. Verify pinion angle against the service manual.
11. 11

    Install U-bolts and plate
    Place the U-bolt plate on top of the axle in the correct orientation. Install the U-bolts over the axle and through the holes in the spring and plate. Thread all four U-bolt nuts onto the U-bolts and tighten in a criss-cross pattern gradually. Due to lack of manufacturer specifications in the database, follow OEM service manual torque specifications. Ram 3500 leaf spring U-bolt torque is typically higher than light-duty trucks (frequently in the 150+ ft-lbs range with a staged tightening and re-torque procedure) — do not guess; verify the exact value in the service manual. Recheck tightness after test drive.
12. 12

    Tighten spring mounting bolts
    With the vehicle weight now on the suspension (axle raised to ride height), tighten the front spring eye bolt and both rear shackle bolts. Due to lack of manufacturer specifications in the database, follow OEM service manual torque specifications for the front spring eye bolt and rear shackle bolts individually. Do not apply a single guessed value — verify each fastener's torque in the service manual. These bolts must be tightened at ride height to prevent premature bushing failure.
13. 13

    Reinstall shock absorber
    Reconnect the shock absorber lower mounting bolt and tighten to specification per OEM service manual. Ensure the shock is not twisted or binding.

Reassembly

1. Reinstall wheel and hand-tighten lug nuts
2. Lower vehicle to ground and remove jack stands
3. Torque wheel lug nuts to specification (typically 135 ft-lbs for Ram 3500) in a star pattern
4. Repeat procedure for opposite side if replacing both springs
5. All leaf spring mounting bolts should be torqued with vehicle at normal ride height to prevent bushing wind-up

Verification

• Test drive vehicle and listen for any unusual noises from the rear suspension
• Check that vehicle sits level side-to-side
• After 50-100 miles of driving, re-torque all U-bolt nuts as they may settle
• Inspect all mounting hardware for proper tightness
• Verify no contact between spring and frame or other components through full suspension travel

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