How to Install an Upper Ball Joint in a 1994 Dodge RAM B250

The Dodge B-series vans debuted back in 1971, after the elimination of the A-series lineup of vans, which lasted from 1964 through 1970. In 1981, Dodge added the Ram name to the full-size van line up. The 1994 Dodge Ram B250 came standard with a 3.9-liter V-6 engine that pushed out 175 horsepower. The upper ball joints on the B250s front suspension are an odd setup, as they are a screw-in type, as opposed to a press-in type. This makes removing and installing an upper ball joint on the 1994 B250 a more straightforward task than most other vehicles of its era.

Instructions

Removal

1

Loosen the lug nuts on the wheel with the failed ball joint, using a ratchet and socket. Lift the front of the van with a floor jack and slide jack stands under the vehicles frame rails. Lower the B250 onto the jack stands. Remove the lug nuts from the wheel and pull the wheel from the hub.

2

Slide the jack under the lower control arm and lift the jack until it contacts the lower control arm. Do not apply any upward force.

3

Pull the cotter pin from the upper ball joints stud, using needle-nose pliers. Remove the nut from the ball joint stud, using a ratchet and socket.

4

Set a ball joint separator Chrysler too No. C-3564-A between the upper ball joints stud and the lower part of the steering knuckle, with its threaded side facing up. Turn the threaded end of the separator counterclockwise with a combination wrench until it applies upward force to the ball joint stud. Do not attempt to force the ball joint out with the separator, as you may break the separator.

5

Hit the upper part of the steering knuckle around the ball joint sharply with a hammer to break the ball joints threads free from the steering knuckle. Cut the seal from the old ball joint, if present, using a utility knife.

6

Unscrew the ball joint from the upper control arm, using a 3/4-inch-drive breaker bar and a ball joint wrench Chrysler tool No. C-3561. Remove the ball joint and separator from the vehicle.

Installation

7

Hand-thread the new ball joint into the upper control arm, the\n tighten it to 125 foot-pounds with a torque wrench and ball joint wrench. If you see a 0.01 to 0.05-inch gap between the base of the ball joints hex head and the top of the upper control arm, this is normal.

8

Press a new ball joint boot, which comes with the new ball joint, over the ball joints stud until you feel that it will not slide any farther down the tapered stud. Pull the base of the boot downward until it seals on the ball joints tapered body.

9

Thread the new ball joint nut, which comes with the ball joint, onto the ball joint stud. Tighten the nut to 135 foot-pounds, using a torque wrench and socket. Verify that a valley in the nuts castellated top aligns with the hole through the ball joint stud. If the valley does not line up, lightly tighten the nut until it does line up.

10

Insert the new cotter pin, which also comes with the ball joint, through the ball joints stud, then bend its legs in opposite directions with needle-nose pliers.

11

Tighten the zirk fitting, which comes with the new ball joint, into the top of the ball joint, if its not preinstalled, and snug it with a box-end wrench.

12

Connect a grease gun filled with multipurpose grease to the zirk fitting. Pump grease into the ball joint until its boot feels tight. Do not fill it to the point that grease oozes from the boot. Remove the floor jack from under the lower control arm.

13

Install the wheel on the front hub and hand-tighten the lug nuts. Raise the B250 off the jack stands and remove the stands. Lower the van to the ground. Tighten the lug nuts, in a crisscross pattern, to between 85 to 110 foot-pounds, if the lug nuts have 1/2 x 20 threads, or between 175 and 225 foot-pounds, if they have 5/8 x 18 threads.