Tie Rod End - Outer

This procedure covers removal and replacement of the outer tie rod end on a 2007 Ram 3500 with 4WD, including proper alignment considerations.

Warnings

Tools required

Parts

• Outer tie rod end × 1 — Use OEM specification or quality aftermarket
• Castle nut (if not included with tie rod) × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen lug nuts on the affected front wheel while vehicle is on the ground
4. Raise front of vehicle with floor jack and support securely on jack stands rated for heavy-duty trucks
5. Remove wheel and tire assembly
6. Spray penetrating oil on tie rod end castle nut, stud taper, and tie rod jam nut; allow to soak for 10-15 minutes

Procedure

1. 1

   Mark alignment reference
   Before removing the old tie rod end, measure and record the distance from the inner tie rod boot edge to the outer tie rod end center or outer edge. This measurement will help maintain approximate alignment when installing the new part. Alternatively, count the number of visible threads on the tie rod shaft between the jam nut and outer tie rod end.
2. 2

   Remove cotter pin and castle nut
   Straighten and remove the cotter pin from the tie rod end castle nut using pliers. Discard the old cotter pin. Using the appropriately sized socket (verify the nut size on the vehicle; commonly larger on the 3500 heavy-duty linkage), remove the castle nut from the tie rod end stud. Keep the nut if the new tie rod end did not include a replacement nut.
3. 3

   Separate tie rod end from knuckle
   Position the tie rod end separator tool (pickle fork or ball joint separator) between the steering knuckle and tie rod end. Strike the tool firmly with a hammer to break the taper fit, or use a threaded-style separator if available. Apply force in a controlled manner to avoid damaging the knuckle or surrounding components. The tie rod end stud should pop free from the knuckle taper.
4. 4

   Loosen jam nut
   Using the appropriately sized wrench on the jam nut (verify size on the vehicle) and holding the inner tie rod shaft with an adjustable wrench or locking pliers, loosen the jam nut. Do not remove the jam nut completely yet. If the jam nut is severely corroded, apply additional penetrating oil and allow more soak time.
5. 5

   Remove outer tie rod end
   Hold the inner tie rod shaft stationary with locking pliers or an adjustable wrench to prevent it from spinning. Thread the outer tie rod end counterclockwise off the inner tie rod shaft. Count the number of complete turns required to remove it, or note the final position of the jam nut on the threads for reference during installation.
6. 6

   Clean threads and inspect components
   Use a wire brush to clean the threads on the inner tie rod shaft. Inspect the inner tie rod boot for tears, cracks, or grease leakage. Check the steering knuckle taper for damage or excessive wear. If the boot is damaged or the knuckle taper is wallowed out, additional repairs will be necessary before proceeding.
7. 7

   Install new outer tie rod end
   Thread the new outer tie rod end onto the inner tie rod shaft clockwise, using the same number of turns or measurement recorded during removal. Apply a small amount of thread sealant to the threads if desired. Leave the jam nut loose for now to allow final adjustment.
8. 8

   Insert tie rod stud into knuckle
   Insert the tie rod end stud into the steering knuckle taper. Ensure the stud seats fully into the taper bore. Install the castle nut onto the stud and tighten by hand until snug. The nut should draw the taper fully into the knuckle.
9. 9

   Torque castle nut and install cotter pin
   Tighten the castle nut to manufacturer specifications. Torque the castle nut to the factory specification for this vehicle (verify in the FSM; the 2007 Ram 3500 outer tie rod stud nut spec is approximately 55 ft-lbs), then advance the nut as needed to align the next castle slot with the cotter pin hole in the stud. Never loosen the nut to align the cotter pin hole. Install a new cotter pin through the castle nut and stud, then bend the ends of the pin to secure it.
10. 10

    Verify alignment reference and tighten jam nut
    Check that the outer tie rod end is positioned according to your initial measurement or thread count. Make minor adjustments if necessary. Once satisfied with the position, hold the outer tie rod end with a wrench to prevent rotation, and tighten the jam nut against the outer tie rod end firmly using a 19mm wrench. Typical jam nut torque is 35-40 ft-lbs.
11. 11

    Reinstall wheel and lower vehicle
    Reinstall the wheel and tire assembly onto the hub. Thread all lug nuts by hand first to ensure proper seating. Lower the vehicle until the tire contacts the ground but the suspension is not fully loaded. Torque the lug nuts in a star pattern to the factory specification for this vehicle (approximately 145 ft-lbs for the 2007 Ram 3500; verify in the FSM). Fully lower the vehicle and remove jack stands.

Reassembly

1. Double-check that the castle nut is properly torqued and the cotter pin is securely installed
2. Verify the jam nut is tight against the outer tie rod end to prevent loosening
3. Inspect for any tools or parts left in the wheel well area

Verification

• Start the engine and turn the steering wheel slowly from lock to lock while stationary, listening for unusual noises or binding
• Test drive the vehicle at low speed in a safe area to verify steering response and check for pulling to one side
• Visually inspect the tie rod end installation after the test drive to ensure nothing has loosened
• Schedule a professional wheel alignment as soon as possible, as toe adjustment will be necessary after tie rod replacement

More procedures for this vehicle