Strut Assembly - Front

This procedure replaces the front strut assemblies on a 2007 Ram 3500 with 5.9L Cummins diesel engine, including removal of the strut from the knuckle and tower, and installation of new strut assemblies.

Warnings

Tools required

Parts

• Front strut assembly (complete) × 2 — Use OEM specification or quality aftermarket
• Strut-to-knuckle bolts (if TTY) × 4 — Verify if bolts are torque-to-yield

Preparation

1. Park vehicle on level, solid surface and engage parking brake firmly
2. Place wheel chocks behind rear wheels on both sides
3. Loosen front wheel lug nuts 1/2 turn while vehicle is on ground
4. Raise front of vehicle using manufacturer-approved lift points and secure on jack stands rated for vehicle weight
5. Remove both front wheels completely
6. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes if visible corrosion is present
7. Verify you have complete strut assemblies (strut, spring, and mount pre-assembled). If replacing only strut cartridges, a spring compressor is mandatory

Procedure

1. 1

   Support lower control arm
   Position a floor jack under the front axle to support the suspension weight. Raise jack until it just contacts and slightly loads the axle, but do not lift the vehicle. This supports the axle when the shock absorber is disconnected.
2. 2

   Disconnect sway bar end link (if necessary)
   If the sway bar end link interferes with strut removal, remove the upper nut connecting the end link to the strut using an 18mm wrench while holding the stud with a 15mm wrench or socket. Note orientation and position for reassembly. On some configurations, the end link can remain connected.
   Torque spec

   Sway Bar End Link Nuts55 Nm (41 lb-ft)
3. 3

   Remove strut-to-knuckle bolts
   Locate the two bolts connecting the bottom of the strut to the steering knuckle. These are large 21mm bolts. Use a breaker bar if necessary to break torque. Remove both bolts completely and set aside. Inspect bolts for signs of necking or stretching - if present, these are TTY bolts and must be replaced. Support the strut by hand as you remove the second bolt.
   ⚠The strut will pivot away from the knuckle once both bolts are removed. Maintain control to prevent damage to brake lines or ABS wiring.
   Torque spec

   Strut-to-Knuckle Bolts150 Nm (111 lb-ft)
4. 4

   Access strut tower mounting nuts
   Open the hood and locate the strut tower on the inner fender area. Remove any plastic covers or insulation obscuring access to the three upper mounting nuts. On the driver side, you may need to move the air filter housing slightly for better access.
5. 5

   Remove upper strut tower nuts
   Using a 15mm socket, remove the three nuts securing the strut mount to the strut tower. Do NOT remove or loosen the large center nut at this time - it holds the compressed spring. Remove only the three outer nuts that secure the mount to the tower. Keep nuts organized for reinstallation.
   ⚠️DO NOT loosen the center nut on top of the strut mount. This nut retains the compressed coil spring and loosening it without a spring compressor will cause violent release of spring energy.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
6. 6

   Remove strut assembly
   Carefully lower the floor jack supporting the control arm slightly to create clearance. Guide the strut assembly down and out from the wheel well. The top studs will pull through the strut tower holes. Maneuver the assembly past the brake components and remove from vehicle. This is a heavy component weighing 25-35 lbs - use proper lifting technique.
7. 7

   Inspect mounting areas
   Clean the strut tower mounting surface with a wire brush, removing any rust or debris. Inspect the strut tower for cracks, damage, or rust perforation. Check the steering knuckle strut mounting holes for elongation or damage. Clean the knuckle mounting surface and bolt holes thoroughly.
8. 8

   Install new strut assembly to tower
   Guide the new complete strut assembly into position, inserting the upper mount studs through the strut tower holes. Ensure the mount is properly oriented with the studs fully through the holes. Thread the three upper nuts onto the studs by hand. Do not torque at this time - just snug them finger-tight to hold the assembly in place.
9. 9

   Connect strut to knuckle
   Raise the floor jack under the control arm to lift the knuckle and align the strut mounting holes with the knuckle bracket. You may need to pivot the knuckle slightly or use a pry bar to align holes. Insert the strut-to-knuckle bolts (use new bolts if originals were TTY) and thread nuts on by hand. Ensure bolts are inserted from the correct direction per factory orientation.
10. 10

    Torque strut-to-knuckle bolts
    Using a torque wrench and 21mm socket, torque both strut-to-knuckle bolts to 150 Nm (111 lb-ft). Torque each bolt in stages (50%, 75%, 100%) rather than in one pull. Verify both bolts reach specified torque. These are critical fasteners for steering and suspension integrity.
    ⚠️These bolts are CRITICAL safety fasteners. Verify torque specification is achieved. Under-torquing can result in bolt failure and loss of vehicle control.
    Torque spec

    Strut-to-Knuckle Bolts150 Nm (111 lb-ft)
11. 11

    Torque strut tower nuts
    From under the hood, torque the three upper strut tower nuts to 50 Nm (37 lb-ft) using a torque wrench and 15mm socket. Torque in a star pattern to ensure even loading of the mount. Again, do NOT touch the center nut - it should remain at factory torque from the complete strut assembly.
    Torque spec

    Strut Tower Nuts50 Nm (37 lb-ft)
12. 12

    Reconnect sway bar end link
    If the sway bar end link was disconnected in Step 2, reconnect it now. Position the end link in its original orientation and install the upper nut. Hold the stud with a 15mm wrench while torquing the nut to 55 Nm (41 lb-ft) with an 18mm wrench or socket.
    Torque spec

    Sway Bar End Link Nuts55 Nm (41 lb-ft)
13. 13

    Repeat for opposite side
    Perform Steps 1-12 for the opposite side front strut. Both front struts should always be replaced as a pair to maintain balanced handling and ride characteristics. Ensure all fasteners are torqued to specification on both sides.
14. 14

    Reinstall wheels and lower vehicle
    Install both front wheels and thread lug nuts by hand. Lower vehicle to ground and remove jack stands. With vehicle weight on wheels, torque lug nuts to manufacturer specification (typically 135-160 lb-ft for this vehicle) in a star pattern.

Reassembly

1. Verify all fasteners are torqued to specification, particularly the strut-to-knuckle bolts and upper strut tower nuts
2. Ensure no tools or parts were left in the engine bay or wheel wells
3. Reinstall any plastic covers or air filter components that were moved for access
4. Remove wheel chocks from rear wheels

Verification

• Test drive vehicle in a safe area at low speed (under 25 mph). Listen for any clunking, rattling, or unusual noises from front suspension
• Verify steering returns to center properly and vehicle tracks straight with hands off wheel
• Check for any fluid leaks from strut assemblies after test drive
• Bounce each front corner of vehicle - struts should dampen motion within 1-2 cycles without excessive bouncing
• SCHEDULE FRONT-END ALIGNMENT IMMEDIATELY. This is not optional - strut replacement affects wheel alignment and tire wear. Driving without alignment can cause rapid tire wear and poor handling
• After 50-100 miles, re-verify torque on all fasteners, particularly strut-to-knuckle bolts

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