Upper Control Arm - Front

This procedure covers the removal and replacement of the front upper control arm on a 2007 Ram 3500 4WD with 5.9L Cummins diesel engine, including ball joint separation and alignment considerations.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM Mopar or quality aftermarket for 4WD models
• Upper ball joint nut × 1 — Replace if damaged or non-prevailing torque type

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle and support with jack stands under frame rails
5. Remove front 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 the lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the weight of the knuckle assembly and prevent sudden dropping when the upper ball joint is separated. Raise jack just enough to lightly compress the coil spring.
2. 2

   Remove upper ball joint nut
   Remove the cotter pin from the upper ball joint castle nut. Using a 21mm socket, remove the upper ball joint nut. Do not reuse the nut if it is a one-time-use prevailing torque type. Keep track of any washers or spacers.
3. 3

   Separate the upper ball joint from knuckle
   Using a ball joint separator tool or pickle fork, carefully separate the upper ball joint stud from the steering knuckle. Strike the separator with a hammer if necessary, but avoid direct blows to the ball joint stud threads. The knuckle will drop slightly when separated—the floor jack will prevent it from dropping completely.
   ⚠Use of a pickle fork will damage the ball joint boot. Only use if replacing the entire control arm assembly.
4. 4

   Mark alignment cam position
   Before removing the control arm, mark the position of the alignment cam bolt at the frame mount using a paint pen or scribe. This will provide a reference point for initial reinstallation and minimize alignment changes. Note the orientation of any washers or cam adjusters.
5. 5

   Remove front control arm mounting bolt
   Using an 18mm wrench to hold the nut and a 21mm socket on the bolt head, remove the front control arm mounting bolt from the frame bracket. Note the orientation of the bolt and any alignment cams or eccentric washers for reinstallation.
6. 6

   Remove rear control arm mounting bolt
   Using an 18mm wrench on the nut and 21mm socket on the bolt head, remove the rear control arm mounting bolt from the frame bracket. The control arm can now be removed from the vehicle. Note any shims or spacers and their positions.
7. 7

   Inspect and clean mounting points
   Clean the frame mounting brackets and knuckle ball joint taper with a wire brush. Inspect the frame mounts for cracks, elongated holes, or damage. Check the steering knuckle ball joint bore for damage or excessive wear. Replace components as necessary.
8. 8

   Install new upper control arm to frame
   Position the new upper control arm into the frame brackets, aligning with the marks made during disassembly. Install both front and rear mounting bolts with any alignment cams, shims, or washers in their original positions. Thread nuts onto bolts but do not tighten completely yet—leave them finger tight to allow for adjustment.
9. 9

   Connect ball joint to knuckle
   Carefully raise the steering knuckle using the floor jack until the upper ball joint stud seats fully into the knuckle taper. Ensure the stud is properly centered in the bore. Install the ball joint nut and tighten until snug. Verify the stud is fully seated before final torquing.
10. 10

    Torque ball joint nut and install cotter pin
    Torque the upper ball joint nut to specification (typically 60-75 ft-lbs for this application, but verify with manufacturer specifications). Align the castle nut slots with the cotter pin hole—tighten further if necessary to align, never loosen. Install a new cotter pin and bend tabs to secure.
11. 11

    Torque control arm mounting bolts
    With the vehicle weight on the suspension (floor jack supporting lower control arm at ride height), torque the front and rear upper control arm mounting bolts. Typical specification is 125-140 ft-lbs for both bolts. Torque the bolt head, not the nut, while holding the nut stationary. Ensure cam adjusters remain in marked position.
12. 12

    Remove jack and reinstall wheel
    Carefully lower and remove the floor jack from under the lower control arm. Reinstall the wheel and hand-tighten lug nuts. Lower vehicle to ground and torque lug nuts to 145 ft-lbs in a star pattern.

Reassembly

1. Verify all fasteners are properly torqued before road test
2. Ensure cotter pin is properly installed and secured in ball joint nut
3. Check that no tools or parts were left in wheel well area
4. If replacing both sides, repeat procedure for opposite side before alignment

Verification

• Test drive vehicle at low speed and verify no unusual noises from front suspension
• Check for proper steering feel and control—there should be no play or looseness
• Visually inspect all connections to ensure proper installation
• Schedule a professional four-wheel alignment as soon as possible to prevent premature tire wear and ensure proper handling
• After 50-100 miles, re-check all mounting bolt torque to ensure nothing has loosened during break-in

Related trouble codes on this vehicle

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