Radius Arm Bushing

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

Warnings

Tools required

Parts

• Radius arm bushing kit (front) × 2 — Use OEM specification or equivalent
• Radius arm bushing kit (rear) × 2 — Use OEM specification or equivalent

Preparation

1. Park vehicle on level, solid ground and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is still on ground
4. Raise front of vehicle and support securely on jack stands placed on frame rails
5. Remove front wheels completely
6. Apply penetrating oil to all radius arm mounting bolts and allow to soak for 15-20 minutes
7. Clean area around radius arm mounts with wire brush to remove dirt and corrosion

Procedure

1. 1

   Support the front axle
   Position a floor jack under the front axle housing near the radius arm mounting point. Raise jack until it just contacts the axle and supports some weight, but does not lift the vehicle off the jack stands. This relieves tension on the radius arm.
2. 2

   Remove front radius arm mounting bolt
   Locate the front radius arm mounting bolt at the axle housing. Using a 24mm socket and breaker bar, remove the nut from the front mounting bolt. Drive the bolt out using a punch or long drift. You may need to use a pry bar to slightly separate the mounting bracket to free the bolt.
3. 3

   Remove rear radius arm mounting bolt
   Locate the rear radius arm mounting bolt at the frame bracket. Using a 21mm socket and breaker bar, remove the nut and flag bolt that secures the radius arm to the frame-mounted bracket. Note the orientation of the flag bolt for reinstallation. The radius arm can now be removed from the vehicle.
4. 4

   Inspect radius arm
   With the radius arm removed, inspect the arm itself for cracks, bends, or damage. If the arm is damaged, it should be replaced. Check the bushing mounting areas for wear or elongation of the mounting holes.
5. 5

   Remove front bushing from radius arm
   Using a hydraulic press or bushing removal tool, press out the old front bushing from the radius arm. The bushing is pressed through the arm eye. Apply steady, even pressure and ensure the arm is properly supported to prevent distortion. Clean the bushing bore thoroughly with a wire brush and solvent.
6. 6

   Install new front bushing
   Position the new front bushing in the radius arm eye, ensuring proper orientation (some bushings have a specific directional installation). Using the hydraulic press or installation tool, press the new bushing into place until it is fully seated and centered in the mounting eye. The bushing should be flush on both sides.
7. 7

   Remove rear bushing from radius arm
   Using the hydraulic press or bushing removal tool, press out the old rear bushing from the opposite end of the radius arm. This bushing typically includes a sleeve that must be removed as well. Clean the bushing bore thoroughly.
8. 8

   Install new rear bushing
   Install the new rear bushing with its sleeve into the radius arm eye. Ensure the bushing is properly oriented according to manufacturer instructions. Press the bushing into place until fully seated and centered. Verify that any internal sleeves are properly aligned.
9. 9

   Reinstall radius arm to axle
   Position the radius arm back onto the vehicle, inserting the front bushing onto the axle mounting bracket first. Install the front mounting bolt through the axle bracket and radius arm bushing. Thread the nut on hand-tight but do not torque yet. The suspension should be at normal ride height when final tightening occurs.
10. 10

    Reinstall rear radius arm mount
    Align the rear of the radius arm with the frame-mounted bracket. Install the flag bolt in the correct orientation (flag facing the direction noted during removal). Thread the nut on hand-tight. You may need to use a pry bar or jack to align the holes.
11. 11

    Lower vehicle to load suspension
    Carefully lower the vehicle from the jack stands until the full weight of the vehicle is resting on the suspension at normal ride height. The wheels should still be off the ground by 1-2 inches, or you can reinstall the wheels first. This loads the bushings in their normal operating position.
12. 12

    Torque all fasteners
    With the suspension at normal ride height, torque the front radius arm bolt nut and rear flag bolt nut to specification. Refer to the factory service manual for the exact torque specification for the front and rear radius arm fasteners; these large safety-critical bolts must not be estimated. Do not guess a value. Ensure fasteners are torqued evenly and check for any binding in the suspension.
13. 13

    Repeat for opposite side
    Repeat steps 1-12 for the radius arm on the opposite side of the vehicle. Both radius arms should be serviced together to maintain even suspension characteristics.

Reassembly

1. Reinstall front wheels and torque lug nuts to specification (typically 135 ft-lbs for this vehicle)
2. Lower vehicle completely to the ground
3. Remove jack stands and floor jack
4. Perform a final check of all fasteners to ensure they are tight
5. Test drive vehicle at low speed to verify proper operation before returning to normal use

Verification

• Visually inspect that all fasteners are installed and properly tightened
• Check that radius arms move freely without binding when suspension is cycled
• Verify no unusual noises from front suspension when driving over bumps
• Confirm steering and handling feel normal with no pulling or vibration
• Re-check torque on all fasteners after 50-100 miles of driving
• Consider having alignment checked if vehicle pulls or tire wear was uneven before service

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