Tie Rods - Both Sides

Replace both inner and outer tie rod ends on the front axle of a 2007 Ram 3500 4WD with 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Outer tie rod end - driver side × 1 — ES3523 or OEM equivalent
• Outer tie rod end - passenger side × 1 — ES3523 or OEM equivalent
• Inner tie rod end - driver side × 1 — ES3522 or OEM equivalent
• Inner tie rod end - passenger side × 1 — ES3522 or OEM equivalent
• Castle nuts for tie rod ends × 4 — Often included with tie rod ends
• Cotter pins × 4 — 1/8" diameter

Preparation

1. Park vehicle on level ground and set parking brake firmly
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands under the frame rails
5. Remove both front wheels completely
6. Spray all tie rod end jam nuts, castle nuts, and tapers with penetrating oil and allow to soak for 10-15 minutes
7. Turn steering wheel to center position and lock in place (turn off and remove key)

Procedure

1. 1

   Mark alignment reference points
   Before removing any parts, measure and record the exposed thread length on each outer tie rod end from the jam nut to the end of the threads. Use paint marker or tape to mark the position of each outer tie rod end relative to the inner tie rod threads. This helps restore approximate toe setting during reassembly. Also count and record the number of visible threads between the jam nut and the steering knuckle on each side.
2. 2

   Remove outer tie rod end cotter pins and castle nuts
   Straighten and remove the cotter pins from the outer tie rod end castle nuts at the steering knuckles on both sides. Remove the castle nuts completely using appropriate socket or wrench. Note: verify the castle nut size on the vehicle before selecting a socket, as HD Ram tie rod nuts are often larger than light-duty applications. Do not reuse old cotter pins.
3. 3

   Separate outer tie rod ends from steering knuckles
   Use a tie rod end separator tool (pickle fork or ball joint separator) to separate the outer tie rod end taper from the steering knuckle. Position the tool between the knuckle and tie rod end mounting boss, then strike firmly with hammer or tighten forcing screw until the taper releases. The tie rod end will pop free suddenly. Repeat for both sides.
4. 4

   Remove outer tie rod ends from inner tie rods
   Hold the flat sections of each inner tie rod with locking pliers or vise grips to prevent rotation. Loosen the jam nut on each outer tie rod end using large adjustable wrench. Count the number of turns as you unscrew each outer tie rod end completely from the inner tie rod. Record these turn counts for each side to aid reassembly alignment.
5. 5

   Remove inner tie rod end cotter pins and castle nuts
   Locate the inner tie rod end connection points at the steering linkage (center link/drag link). Remove the cotter pins and castle nuts from both inner tie rod ends. These castle nuts are typically 1-3/8" or 36mm. Support the steering linkage with one hand while removing nuts to prevent it from dropping suddenly.
6. 6

   Separate inner tie rod ends from steering linkage
   Use the tie rod end separator tool to separate each inner tie rod end taper from the center link. Position tool carefully to avoid damaging the steering linkage boots or drag link. Strike firmly or apply pressure until the taper releases. Remove both inner tie rod assemblies completely from the vehicle.
7. 7

   Clean and inspect mounting points
   Use wire brush to clean the taper holes in the steering knuckles and center link on both sides. Remove any rust, dirt, or debris. Inspect the taper seats for damage, cracks, or excessive wear. Check steering linkage boots for tears or damage. Any damaged boots should be replaced at this time.
8. 8

   Install new inner tie rod ends
   Install new inner tie rod ends into the center link taper holes. Ensure tapers are clean and seat fully. Install new castle nuts and tighten to the factory specification (verify in the 2007 Ram 3500 FSM — heavy-duty steering taper nuts are commonly higher than light-duty, often around 90 ft-lbs). Tighten until the next castle slot aligns with the cotter pin hole. Install new cotter pins and bend ends to secure. Tighten until the next castle slot aligns with the cotter pin hole. Install new cotter pins and bend ends to secure. Repeat for both sides.
9. 9

   Thread outer tie rod ends onto inner tie rods
   Apply a light coat of anti-seize compound to the inner tie rod threads. Thread each outer tie rod end onto its corresponding inner tie rod the same number of turns you counted during removal, aligning with your reference marks. Thread the jam nuts onto the inner tie rods but leave them loose for now. This provides a starting point for alignment.
10. 10

    Install outer tie rod ends into steering knuckles
    Insert the outer tie rod end tapers into the steering knuckle taper holes. Ensure tapers seat fully and are clean. Install new castle nuts and tighten to the factory specification (verify in the 2007 Ram 3500 FSM — heavy-duty tie rod taper nuts are commonly around 90 ft-lbs, not the light-duty range). Continue tightening only as needed to align castle nut slots with cotter pin holes. Install new cotter pins and bend ends securely. Continue tightening only as needed to align castle nut slots with cotter pin holes. Install new cotter pins and bend ends securely. Repeat for both sides.
11. 11

    Tighten jam nuts
    Hold each outer tie rod end with vise grips or wrench to prevent rotation. Use large adjustable wrench to tighten the jam nuts against the outer tie rod ends. Verify the correct jam nut or adjuster clamp torque in the 2007 Ram 3500 FSM (some HD steering uses pinch/clamp bolts rather than jam nuts). Tighten to the factory-specified value to lock the adjustment in place. Verify reference marks still align properly after tightening.
12. 12

    Verify installation and range of motion
    Visually inspect all tie rod end connections to ensure tapers are fully seated, all castle nuts are properly installed with cotter pins, and jam nuts are tight. Have an assistant turn the steering wheel slowly from lock to lock while you observe both tie rod assemblies for binding, interference, or unusual movement. Listen for any popping or clicking sounds.

Reassembly

1. Reinstall both front wheels and hand-tighten lug nuts
2. Lower vehicle to ground and torque lug nuts to 135 ft-lbs in star pattern
3. Test drive vehicle at low speed in safe area to verify steering response
4. Verify no unusual noises, vibrations, or pulling during straight-line driving and turning

Verification

• Schedule professional front end alignment as soon as possible - this is mandatory after tie rod replacement
• After alignment, verify steering wheel is centered when driving straight
• Check that vehicle tracks straight without pulling to either side
• Re-torque all tie rod castle nuts and jam nuts after 50-100 miles of driving
• Inspect cotter pins to ensure they remain properly secured

More procedures for this vehicle