Ram 1500, 2500, 3500, 2WD and 4WD, 2001-2005

Steering Knuckle

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Removal & Installation



  1. Raise and safely support the vehicle. Place a jack under outer end of lower suspension arm.
  2.  
  3. Remove wheel and tire assembly.
  4.  
  5. Remove disc brake caliper and rotor.
  6.  
  7. Remove the rotor dust shield.
  8.  
  9. Remove the wheel speed sensor.
  10.  
  11. Remove tie rod from steering knuckle arm.
  12.  
  13. Remove cotter pins and nuts from upper and lower ball joints. Discard the cotter pins
  14.  
  15. Use Ball Joint Remover C-3564-A to separate upper and lower ball joints from steering knuckle.
    NOTE
    It may be necessary to also strike the knuckle with a hammer to separate the ball joints from the knuckle.



    Click image to see an enlarged view

    Fig. Exploded view of the steering knuckle & related components

    Exploded view of the steering knuckle & related components
  16.  

To install:

  1. Remove tool and steering knuckle assembly.
  2.  
  3. Secure the steering knuckle in a vise to remove the steering arm from the steering knuckle.
  4.  
  5. Mount the steering knuckle in a vise and install the steering arm on the steering knuckle and tighten nuts to:
    1. LD 5/8 nut: 217 ft. lbs. (294 Nm)
    2.  
    3. HD 3/4 nut: 225 ft. lbs. (330 Nm)
    4.  

  6.  
  7. Position steering knuckle on upper and lower ball joints and install nuts. Tighten upper nut to 135 ft. lbs. (183 Nm). Install new cotter pins.
  8.  
  9. Tighten the lower nut to:
    1. LD 11/16 nut: 135 ft. lbs. (183 Nm)
    2.  
    3. HD 3/4 nut: 175 ft. lbs. (237 Nm)
    4.  

  10.  
  11. Install the wheel speed sensor.
  12.  
  13. Install brake rotor dust shield on steering knuckle and tighten bolts to 18 ft. lbs. (24 Nm).
  14.  
  15. Install rotor and disc brake caliper.
  16.  
  17. Install tie rod to steering knuckle arm.
  18.  
  19. Install wheel and tire assembly and lower the vehicle.
  20.  
  21. Check the wheel alignment.
  22.  

Independent Front Suspension
  1. Raise and support the vehicle.
  2.  
  3. Remove the wheel.
  4.  
  5. Remove the brake caliper and rotor, shield and ABS wheel speed sensor, if equipped.
  6.  
  7. Remove the front halfshaft nut (if equipped)
  8.  
  9. Remove the cotter pin and nut from the tie rod. Disconnect the tie rod from the steering knuckle with Remover 8677, or equivalent.
    WARNING
    When installing Remover 8677 to separate the ball joint, be careful not to damage the ball joint seal.

  10.  
  11. Remove the lower ball joint nut. Separate the ball joint from the knuckle with Remover 8677 and remove the knuckle.

    Click image to see an enlarged view

    Fig. Use the special tool (2) to separate the ball joint from the knuckle (1)

    Use the special tool (2) to separate the ball joint from the knuckle (1)
  12.  
  13. For light duty vehicles, remove the upper ball joint nut. Separate the ball joint from the knuckle with Remover 8677 LD. For heavy duty vehicles, remove the upper ball joint nut. Separate the ball joint from the knuckle with Remover 9360HD
  14.  
  15. Remove the hub/bearing from the steering knuckle.
  16.  

To install:


WARNING
The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease.


NOTE
When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle.

  1. Install the hub/bearing to the steering knuckle (1) and tighten the bolts to 120 ft. lbs. (163 Nm) for light duty vehicles or to 130 ft. lbs. (176 Nm) for 2WD heavy duty vehicles.
  2.  
  3. Install the knuckle (1) onto the upper and lower ball joints.
  4.  
  5. Install the upper and lower ball joint nuts (3).

    Click image to see an enlarged view

    Fig. Exploded view of the steering knuckle (1), lower control arm (2) and lower ball joint nut (3)

    Exploded view of the steering knuckle (1), lower control arm (2) and lower ball joint nut (3)
  6.  
  7. Tighten the upper ball joint nut, as follows:
    1. Light Duty (1500 models): 40 ft. lbs. (54 Nm), plus and additional 90° turn
    2.  
    3. Heavy Duty (2500/3500 models): 50 ft. lbs. (68 Nm)
    4.  

  8.  
  9. Tighten the lower ball joint nut, as follows:
    1. Light Duty (1500 models): 38 ft. lbs. (52 Nm), plus and additional 90° turn
    2.  
    3. 2WD Heavy Duty (2500/3500 models): 100 ft. lbs. (135 Nm)
    4.  

  10.  
  11. Remove the hydraulic jack from the lower suspension arm.
  12.  
  13. Install the tie rod end and tighten the nut to 45 ft. lbs. (61 Nm).
  14.  
  15. Install the front halfshaft into the hub/bearing, if equipped.
  16.  
  17. Install the halfshaft nut and tighten to 185 ft. lbs. (251 Nm), if equipped.
  18.  
  19. Install the ABS wheel speed sensor if equipped, and brake shield, rotor and caliper.
  20.  
  21. Install the wheel and tire assembly.
  22.  
  23. Remove the support and lower the vehicle.
  24.  
  25. Perform a wheel alignment.
  26.  

With Link/Coil Front Suspension
  1. Remove the hub bearing and axle shaft.
  2.  
  3. Remove the tie rod or drag link end from the steering knuckle arm.
  4.  
  5. Remove the ABS sensor wire and bracket from the knuckle.
  6.  
  7. Remove the cotter pin from the upper ball stud nut. Remove the upper and lower ball stud nuts.
  8.  
  9. Strike the steering knuckle with a brass hammer to loosen.
  10.  
  11. Remove the knuckle from the axle tube yokes.
  12.  

To install:

  1. Position the steering knuckle on the ball studs.
  2.  
  3. Install and tighten lower ball stud nut to 35 ft. lbs. (47 Nm). Do not install cotter pin at this time.
  4.  
  5. Install and tighten upper ball stud nut to 70 ft. lbs. (94 Nm). Advance nut to next slot to line up hole and install new cotter pin.
  6.  
  7. Retorque lower ball stud nut to 140-160 ft. lbs. (190-217 Nm). Advance nut to next slot to line up hole and install new cotter pin.
  8.  
  9. Install the hub bearing.
  10.  
  11. Install tie-rod or drag link end onto the steering knuckle arm.
  12.  
  13. Install the ABS sensor wire and bracket to the knuckle.
  14.  

 
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