Tie Rod Assembly

This procedure covers the replacement of the outer and/or inner tie rod assemblies on a 2007 Ram 3500 4WD with 5.9L Cummins diesel engine, including removal, installation, and alignment preparation.

Warnings

Tools required

Parts

• Outer tie rod end (driver side) × 1 — Use OEM specification or Moog ES3628
• Outer tie rod end (passenger side) × 1 — Use OEM specification or Moog ES3627
• Inner tie rod assembly (if replacing) × 1 — Use OEM specification
• Castle nut for tie rod end × 2 — Use OEM specification
• Cotter pin × 2 — Standard automotive size

Preparation

1. Park vehicle on level surface and set parking brake
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle with floor jack and secure on jack stands under frame rails
5. Remove front wheels completely
6. Spray all tie rod end tapers, adjustment sleeves, and jam nuts with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Mark tie rod position for reference
   Before removal, measure and mark the tie rod length. Measure from the center of the inner tie rod ball stud to the center of the outer tie rod ball stud and record this measurement. Use a paint marker to mark the position of the outer tie rod end on the threads of the adjustment sleeve. This will help maintain approximate alignment during installation.
2. 2

   Remove outer tie rod end cotter pin and castle nut
   Straighten and remove the cotter pin from the castle nut on the outer tie rod end at the steering knuckle. Use a socket and breaker bar to remove the castle nut from the tie rod end stud. Do not reuse the cotter pin.
3. 3

   Separate outer tie rod from steering knuckle
   Position the tie rod end separator tool between the steering knuckle and the tie rod end. Strike the separator with a hammer to break the taper, or use a pickle fork style separator. Alternatively, use a hammer to strike the side of the steering knuckle boss while applying upward pressure on the tie rod end to pop the taper free. The tie rod end should separate from the knuckle.
   ⚠The tie rod may release suddenly. Support the tie rod to prevent it from falling.
4. 4

   Loosen jam nut on adjustment sleeve
   Use an adjustable wrench or large crescent wrench to loosen the jam nut securing the outer tie rod end to the adjustment sleeve. This nut is typically very tight. The jam nut threads onto the sleeve and locks the tie rod end in position. Do not remove it completely yet.
5. 5

   Remove outer tie rod end
   Count and record the number of visible threads or turns as you unthread the outer tie rod end from the adjustment sleeve. Turn the tie rod end counterclockwise to remove it from the sleeve. This count will help you install the new tie rod end at approximately the same position.
6. 6

   Inspect and prepare new tie rod end
   Compare the new tie rod end to the old one to verify correct parts. Clean the threads on the adjustment sleeve with a wire brush. Apply a light coat of anti-seize compound to the threads of the adjustment sleeve. Ensure the new tie rod end includes the grease fitting.
7. 7

   Install new outer tie rod end
   Thread the new outer tie rod end into the adjustment sleeve to the same number of turns counted during removal, or align it with the paint mark made earlier. The tie rod end should be threaded in to approximately the same depth as the original. Leave the jam nut loose at this time.
8. 8

   Install tie rod end into steering knuckle
   Insert the tie rod end stud into the tapered hole in the steering knuckle. Install the new castle nut and tighten until snug. The stud should pull fully into the taper. Continue tightening the castle nut to the manufacturer's specification (verify exact torque value in the 2007 Ram 3500 service manual before final tightening). Tighten further if necessary to align the castle nut slots with the cotter pin hole.
9. 9

   Install new cotter pin
   Insert a new cotter pin through the castle nut slots and the hole in the tie rod end stud. Bend the ends of the cotter pin to secure it in place, ensuring it cannot back out. Trim excess length if necessary, but ensure the cotter pin is properly retained.
10. 10

    Tighten adjustment sleeve jam nut
    Hold the adjustment sleeve stationary with one wrench while tightening the jam nut against the outer tie rod end with another wrench. Tighten the jam nut (or adjuster clamp bolt, as equipped) securely to the manufacturer's specification (verify exact torque value in the 2007 Ram 3500 service manual). Ensure the sleeve does not rotate during this process, which would change the tie rod length.
11. 11

    Lubricate tie rod end
    If the new tie rod end has a grease fitting, use a grease gun to pump chassis grease into the fitting until new grease appears at the boot seal. Wipe away excess grease. This ensures the ball joint is properly lubricated.
12. 12

    Repeat for opposite side if necessary
    If replacing tie rod ends on both sides, repeat steps 1 through 11 for the opposite side of the vehicle. Ensure both sides are properly secured and lubricated before proceeding.

Reassembly

1. Reinstall front wheels and hand-tighten lug nuts
2. Lower vehicle to ground and remove jack stands
3. Torque wheel lug nuts to 135 ft-lbs in a star pattern
4. Remove wheel chocks

Verification

• Verify all castle nuts are properly torqued and cotter pins are installed and secured
• Verify jam nuts on adjustment sleeves are tight and tie rod ends do not rotate
• Check for proper tie rod end movement by turning the steering wheel lock-to-lock with vehicle on ground
• Test drive vehicle in a safe area at low speed to verify steering response
• Schedule a professional wheel alignment immediately, as toe settings will be incorrect after tie rod replacement

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