Rack and Pinion Boots

Replace the rack and pinion steering gear boots to prevent contamination and maintain proper steering operation on a 2007 Ram 3500 with 5.9L Cummins diesel.

Warnings

Tools required

Parts

• Rack and pinion boot kit (left) × 1 — Use OEM specification
• Rack and pinion boot kit (right) × 1 — Use OEM specification
• Outer tie rod end (if necessary) × 2 — Use OEM specification

Fluids

• ATF+4 — 1 qt

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Place wheel chocks behind rear wheels
3. Center steering wheel and mark position with tape
4. Loosen front wheel lug nuts while vehicle is on ground
5. Raise front of vehicle and support securely on jack stands at frame rails
6. Remove front wheels completely
7. Spray all tie rod end nuts and inner tie rod jam nuts with penetrating oil and allow to soak

Procedure

1. 1

   Access the steering rack
   Remove any skid plates or underbody panels that obstruct access to the steering gear box and linkage/tie rod ends. The 2007 Ram 3500 4WD may have a front skid plate that needs removal. Inspect the existing boots for the type of damage to determine if inner tie rod removal is necessary.
2. 2

   Mark tie rod position
   Before loosening anything, use a marker or paint pen to mark the exact position of the outer tie rod end threads relative to the inner tie rod. Count and record the number of visible threads on both sides. This is critical for maintaining toe alignment. Measure the overall length of each tie rod assembly for reference.
3. 3

   Remove outer tie rod ends
   Remove the castle nut securing the outer tie rod end to the steering knuckle. Use a tie rod end separator or pickle fork to separate the tie rod end taper from the knuckle. Hold the inner tie rod with one wrench while loosening the jam nut with another wrench. Unthread the outer tie rod end, counting the number of full turns for reassembly reference.
4. 4

   Remove damaged boots
   Cut or release the boot clamps at both the rack housing end and the inner tie rod end using side cutters or boot clamp pliers. Slide the old boots off the rack. If boots are severely deteriorated, they may need to be cut away. Clean any debris or old grease from the rack housing and inner tie rod threads using shop towels and a wire brush.
5. 5

   Inspect inner tie rods and rack
   With boots removed, thoroughly inspect the inner tie rod ball joints for excessive play or damage. Check the rack shaft for scoring, rust, or seal damage. Inspect the rack housing mounting bushings for wear. If inner tie rods show significant wear or the ball joint is loose, they should be replaced now before installing new boots.
6. 6

   Prepare new boots
   Verify new boots match the originals in size and shape. Most Ram 3500 rack boots come with new clamps. Apply a light coating of ATF+4 power steering fluid to the inside of the boot and the linkage/joint surface to ease installation and ensure proper sealing. Do not use petroleum-based grease as it degrades rubber components.
7. 7

   Install new boots on rack
   Slide the new boot onto the rack housing first, positioning the small end into the groove on the rack housing. Ensure the boot is fully seated in the housing groove. Install the clamp on the housing end but do not fully tighten yet. Stretch the large end of the boot over the inner tie rod, ensuring it seats properly in its groove.
8. 8

   Secure boot clamps
   Position both boot clamps in their proper grooves. The boot must not be twisted or stretched excessively. Tighten the clamps securely using the appropriate tool for the clamp style (crimp, screw, or pinch type). Ensure clamps are tight enough to seal but not so tight they cut into the boot material. Verify the boot can flex properly without binding.
9. 9

   Reinstall outer tie rod ends
   Thread the outer tie rod ends back onto the inner tie rods, aligning with your reference marks and matching the thread count recorded during disassembly. Thread the jam nut onto the inner tie rod but leave it loose for now. Insert the tie rod end stud into the steering knuckle and install the castle nut.
10. 10

    Tighten tie rod connections
    Torque the outer tie rod end / linkage stud nuts to the factory specification (Ram 3500 HD values are typically well above light-duty specs, commonly in the ~100-185 ft-lb range depending on joint — verify with the service manual as no torque spec was provided in database). Install new cotter pins through castle nuts. Hold the inner tie rod stationary and tighten the jam nuts securely against the outer tie rod ends to lock the adjustment in place.
11. 11

    Check power steering fluid
    With the engine off, check the power steering fluid reservoir. If fluid was lost during the procedure or if the reservoir was topped off to prepare for potential leaks, adjust level to the cold fill mark using ATF+4. Do not overfill as fluid expands when heated.

Reassembly

1. Reinstall any skid plates or underbody panels removed for access
2. Reinstall front wheels and hand-tighten lug nuts
3. Lower vehicle to ground and torque wheel lug nuts to specification in a star pattern
4. Start engine and turn steering wheel slowly lock-to-lock several times to purge air from system
5. Check for leaks at boot clamps and rack housing while assistant turns steering wheel
6. Verify power steering fluid level and top off if necessary with ATF+4
7. Remove steering wheel position tape and verify wheel is still centered

Verification

• Visually inspect both new boots for proper seating and secure clamp installation with no gaps or leaks
• Test drive vehicle at low speed and verify steering response is normal with no binding or unusual noises
• Turn steering wheel lock-to-lock while stationary to check for boot interference or rubbing
• Recheck power steering fluid level after test drive and top off if needed
• Verify no fluid leaks from boot clamps or rack housing
• Check that steering wheel remains centered when driving straight
• Schedule a professional wheel alignment if tie rod position marks were not accurately maintained or if vehicle pulls to one side

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