Upper Control Arm - Rear

This procedure covers the removal and replacement of the rear upper control arm on a 2007 Ram 3500 with 4WD, requiring suspension disassembly and proper alignment afterward.

Warnings

Tools required

Parts

• Rear upper control arm × 1 — Use OEM or equivalent heavy-duty aftermarket
• Upper ball joint castle nut × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Chock front wheels securely
3. Loosen rear wheel lug nuts while vehicle is on ground
4. Raise rear of vehicle and support on jack stands at frame rails behind rear axle
5. Remove rear wheel on side being serviced
6. Spray all control arm bolts and ball joint nut with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Support rear axle
   Position a floor jack under the rear axle housing near the side being worked on. Raise jack just enough to make light contact and support the axle weight. This prevents the axle from dropping excessively when the control arm is removed.
2. 2

   Remove upper ball joint cotter pin and nut
   Locate the upper ball joint where it connects to the steering knuckle. Remove and discard the cotter pin. Using an 18mm socket, remove the castle nut from the upper ball joint stud. Keep track of any washers present.
3. 3

   Separate upper ball joint from knuckle
   Using a ball joint separator or pickle fork, separate the upper ball joint from the steering knuckle. Insert the tool between the knuckle and control arm, then strike with a hammer or apply pressure until the taper releases. Be prepared for the knuckle to drop slightly when separated.
   ⚠The pickle fork method will likely damage the ball joint boot. Only use if replacing the entire control arm assembly.
4. 4

   Remove front control arm mounting bolt
   Locate the front mounting bolt that secures the control arm to the frame bracket. Verify the correct socket size for this fastener against the service manual before beginning. Using a wrench to hold the nut on the opposite side, remove the bolt completely. You may need to use a breaker bar due to torque and corrosion.
5. 5

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt that secures the control arm to the axle bracket. Using the appropriate socket (typically 21mm), remove this bolt while holding the nut on the opposite side. The control arm may need to be pried or maneuvered slightly to relieve binding.
6. 6

   Remove upper control arm
   With both mounting bolts removed and ball joint separated, remove the upper control arm from the vehicle. It may require some maneuvering to clear the frame and axle brackets. Inspect the mounting bushings and brackets for wear or damage.
7. 7

   Clean mounting surfaces
   Use a wire brush to clean the mounting bolt holes in both the frame bracket and axle bracket. Remove any rust, debris, or corrosion. Inspect the bolt threads and replace if damaged. Clean the ball joint taper seat on the steering knuckle.
8. 8

   Install new upper control arm
   Position the new upper control arm into place. Insert the front mounting bolt through the frame bracket and control arm bushing, but do not tighten yet. Then insert the rear mounting bolt through the axle bracket and control arm bushing. Hand-tighten both bolts with nuts started.
9. 9

   Connect ball joint to knuckle
   Align the upper ball joint stud with the tapered hole in the steering knuckle. You may need to use the floor jack to raise or lower the axle slightly for alignment. Insert the ball joint stud into the knuckle until fully seated. Install the new castle nut and tighten until snug.
10. 10

    Torque all fasteners
    With the vehicle weight still supported on jack stands and the axle at ride height (supported by floor jack), torque the front and rear control arm mounting bolts to the manufacturer-specified value (verify with the service manual for this specific vehicle). Torque the ball joint castle nut to the manufacturer-specified value (verify with the service manual for this specific vehicle). Align the castle nut slots with the stud hole and install a new cotter pin. Bend cotter pin ends to secure.
    ℹ️Control arm bushings must be torqued at ride height to prevent premature bushing failure. Do not torque with suspension hanging.
11. 11

    Remove jack and reinstall wheel
    Remove the floor jack from under the axle. Reinstall the wheel and hand-tighten lug nuts. Lower the vehicle to the ground and torque lug nuts to the manufacturer-specified value (verify for this vehicle's wheel configuration; single-rear-wheel and dual-rear-wheel specs differ) in a star pattern.

Reassembly

1. Ensure all fasteners are torqued to specification with the suspension at ride height
2. Verify the new cotter pin is properly installed and bent to prevent loosening
3. Double-check that no tools or parts were left in the wheel well or suspension area

Verification

• Visually inspect all connection points to ensure proper seating and torque
• Bounce the rear suspension to verify the control arm moves freely without binding or unusual noises
• Test drive at low speed in a safe area and listen for any abnormal sounds from the rear suspension
• Schedule a professional four-wheel alignment immediately, as rear camber and caster have been affected
• After 50-100 miles of driving, re-torque all fasteners to specification

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