Lower Control Arm - Front

This procedure covers the removal and replacement of the front lower control arm on a 2007 Ram 3500 with 4WD and 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Lower control arm assembly × 1 — Use OEM specification or Moog RK620433
• Lower ball joint (if not included with control arm) × 1 — Use OEM specification
• Control arm bushing set (if not included) × 1 — Use OEM specification
• Anti-seize compound × 1 — Use copper-based anti-seize

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle and support securely on jack stands at frame rails
5. Remove front wheel on side being serviced
6. Spray all control arm bolts, ball joint nut, and frame mounting points with penetrating oil and allow to soak

Procedure

1. 1

   Support lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the weight of the suspension components. Raise jack just enough to contact the control arm but not lift the vehicle further. This prevents the suspension from dropping suddenly when components are disconnected.
2. 2

   Disconnect sway bar link
   Locate the sway bar end link connection to the lower control arm. Remove the nut securing the sway bar link to the control arm using a 19mm socket while holding the stud with a wrench if necessary. Swing the sway bar link out of the way.
3. 3

   Remove lower ball joint castle nut
   Remove the cotter pin from the lower ball joint castle nut. Using a 21mm socket, remove the castle nut from the ball joint stud. Do not remove the nut completely at first; back it off until it is flush with the end of the stud to protect the threads during separation.
4. 4

   Separate ball joint from knuckle
   Use a ball joint separator tool or pickle fork to break the taper between the ball joint stud and the steering knuckle. Position the tool between the control arm and knuckle, then strike with a hammer or turn the screw mechanism until the joint separates. Once separated, remove the castle nut completely and lower the jack slightly to allow clearance.
5. 5

   Remove front control arm pivot bolt
   Locate the front control arm mounting bolt at the frame rail. This is a large horizontal bolt that passes through the control arm bushing. Remove the nut from the backside using a 21mm socket, then drive the bolt out using a hammer or press it out with the socket. The bolt may be seized; additional penetrating oil and heat may be required.
6. 6

   Remove rear control arm pivot bolt
   Locate the rear control arm mounting bolt at the frame crossmember. Remove the nut from the backside using a 21mm socket, then remove the bolt. This bolt also passes through a bushing and may require persuasion to remove.
7. 7

   Remove lower control arm
   With both pivot bolts removed and the ball joint disconnected, carefully lower the floor jack and maneuver the lower control arm out from the wheel well. You may need to angle it to clear the steering components and frame. Note the orientation and position of any washers or spacers on the pivot bolts for reinstallation.
8. 8

   Prepare new control arm
   Compare the new control arm assembly to the old one to verify correct replacement. If the ball joint is separate, install it into the control arm according to manufacturer instructions (press-fit or bolt-in style). Clean the mounting surfaces on the frame rail and crossmember with a wire brush. Apply anti-seize compound to the threads of the pivot bolts.
9. 9

   Install new control arm to frame
   Position the new lower control arm into place, aligning the front bushing with the frame rail mount and the rear bushing with the crossmember mount. Insert the front pivot bolt from the appropriate direction (note original orientation), then install the nut finger-tight. Insert the rear pivot bolt and install its nut finger-tight. Do not fully torque these bolts yet.
10. 10

    Connect ball joint to knuckle
    Raise the floor jack under the lower control arm to align the ball joint stud with the hole in the steering knuckle. Insert the stud through the knuckle and install the castle nut. Tighten the ball joint stud nut to manufacturer specification (verify exact value in the factory service manual for the 2007 Ram 3500 before final torque). Align the castle nut slots with the stud hole and install a new cotter pin. Bend the cotter pin ends to secure.
11. 11

    Reconnect sway bar link
    Position the sway bar link into the mounting point on the lower control arm. Install the nut and tighten to manufacturer specification (typically 35-45 ft-lbs). If the link stud spins, hold it with a wrench while tightening the nut.
12. 12

    Torque control arm pivot bolts
    With the vehicle's weight on the suspension (suspension at ride height), torque the front and rear control arm pivot bolts to manufacturer specification. This is critical: the bolts must be torqued with the suspension loaded to prevent premature bushing failure. Torque the control arm pivot bolts to the factory-specified value (verify exact torque in the service manual for the 2007 Ram 3500 before final tightening). Remove the floor jack after torquing.
13. 13

    Reinstall wheel and lower vehicle
    Reinstall the wheel and thread the lug nuts by hand. Lower the vehicle until the tire just touches the ground. Torque the lug nuts to manufacturer specification (approximately 145 ft-lbs for this 2007 Ram 3500; verify with service manual) in a star pattern. Fully lower the vehicle and remove jack stands.

Reassembly

1. Ensure all fasteners are torqued to specification with the suspension at ride height
2. Verify new cotter pin is properly installed and secured on ball joint castle nut
3. Double-check that sway bar link is properly connected
4. Clean any spilled penetrating oil or anti-seize from brake components

Verification

• Test drive vehicle at low speed and verify no unusual noises or handling issues
• Check for any looseness in the steering or suspension by performing a bounce test
• Schedule a professional front-end alignment immediately, as camber and caster have been altered
• After 50-100 miles, re-check all fastener torques to ensure nothing has loosened
• Inspect ball joint boot for proper seating and no tears or damage

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