300, Magnum, 2005

Removal & Installation

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2.7L & 3.5L Engines



  1. Disconnect and isolate battery negative cable (2) from battery post.
  2.  
  3. Siphon power steering fluid from pump reservoir.
  4.  
  5. Remove the air cleaner housing and inlet tube to throttle body.
  6.  
  7. Remove the serpentine drive belt.
  8.  
  9. Remove the hose clamp, then the supply hose from pump.
  10.  
  11. Unthread the tube nut, then remove pressure hose from pump.
  12.  
  13. Remove three pump mounting bolts through access holes in pulley.
  14.  
  15. Remove pump from engine bracket.
    WARNING
    Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage pulley and power steering pump.



    Click image to see an enlarged view

    Fig. Remove the mounting bolts (1) through the pulley access holes, then remove the pump (3) from the engine bracket (2)

  16.  
  17. If necessary, remove the pulley as follows:
    1. Mount Puller, Special Tool C-4333, on power steering pump pulley.
    2.  
    3. Mount Puller (with power steering pump) in a vise as shown; Do not mount pump in vise. Placing Puller in vise will keep shaft of pump from turning while removing pulley and help keep tension on Puller and pulley hub.
    4.  
    5. Tighten Puller and remove pulley from shaft of power steering pump.
      NOTE
      Inspect pulley. Replace if pulley is bent, cracked, or loose.



      Click image to see an enlarged view

      Fig. View of the puller (2) installed on the power steering pump pulley. Mount the puller with the pump (1) in the vise as shown

    6.  

  18.  

To install:


WARNING
Do not hammer on power steering pump pulley or pump shaft to install pulley. This action will damage pulley and power steering pump.

  1. If the pulley was removed, perform the following:
    1. Place power steering pump pulley squarely on end of power steering pump shaft.
    2.  
    3. Place Installation Spacer, Special Tool 6936, on top of pump pulley.
      NOTE
      Later build pumps (vehicles built on or after 1/3/05) feature a shaft with internal threads that are not as deep as earlier production, thus requiring a stack of washers, approximately 0.5 in. (13mm) thickness, placed over Spacer 6936, before mounting Installer C-4063C on the pump. To know if a replacement pump requires the stack of washers, measure the depth of the shaft hole. A later build pump will have a depth of 0.78 in. (20mm) while an earlier build pump will have a depth of 1.25 in. (32mm).



      Click image to see an enlarged view

      Fig. Place Installation Spacer (1), Special Tool 6936, on top of pump pulley (2)



      Click image to see an enlarged view

      Fig. Later build pumps have a shaft with internal threads that are not as deep as earlier production, thus requiring a stack of washers, approximately 0.5 in. (13mm) thickness (3), placed over Spacer 6936 (2), before mounting Installer C-4063C (1) on the pump

    4.  
    5. Thread Installer, Special Tool C-4063C, completely into internal threads of power steering pump shaft, then rotate Installer Nut down against Spacer on pump pulley.

      Click image to see an enlarged view

      Fig. Thread Installer (1), Special Tool C-4063C, completely into internal threads of power steering pump shaft, then rotate Installer Nut down against Spacer (2) on pump pulley

    6.  
    7. Ensuring that special tools and pulley remain aligned with pump shaft, tighten Installer Nut, forcing pulley onto power steering pump shaft until Spacer comes in contact with end of pump shaft. When Spacer is against shaft of power steering pump, Installer Nut will no longer rotate.
    8.  
    9. Remove special tools from power steering pump.
    10.  

  2.  
  3. Align the power steering pump with mounting holes on engine bracket.
  4.  
  5. Install three pump mounting bolts through access holes in pulley and engine bracket. Tighten bolts to 21 ft. lbs. (28 Nm).
    NOTE
    Always use a NEW O-ring on the end of the pressure hose.

  6.  
  7. Lubricate NEW O-ring on end of pressure hose with clean power steering fluid.
  8.  
  9. Connect the pressure hose to pump. Tighten the pressure hose tube nut to 35 ft. lbs. (47 Nm) torque.
  10.  
  11. Install the supply hose on the pump. Install the clamp securing hose in place.
  12.  
  13. Install serpentine drive belt.
  14.  
  15. Install air cleaner housing and inlet tube.
  16.  
  17. Connect battery negative cable to battery post. It is important that this is performed properly.
  18.  
  19. Fill the power steering pump reservoir with fluid and perform pump initial operation procedure.
  20.  

5.7L Engine



  1. Disconnect and isolate the negative battery cable from battery post.
  2.  
  3. Siphon power steering fluid from pump reservoir.
  4.  
  5. Remove the air cleaner housing and inlet tube to throttle body.
  6.  
  7. Remove the serpentine drive belt, as outlined in the Engine Mechanical Section.
  8.  
  9. Remove the hose clamp, then the supply hose from pump.
  10.  
  11. Unthread the tube nut, then remove pressure hose from pump.
  12.  
  13. Remove three pump mounting bolts through access holes in pulley.
  14.  
  15. Remove the power steering pump from the engine.

    Click image to see an enlarged view

    Fig. To remove the power steering pump (1), first remove the mounting bolts (2) through the access holes in the pulley

    1. Mount Puller, Special Tool C-4333, on power steering pump pulley.
    2.  
    3. Mount Puller (with power steering pump) in a vise as shown; Do not mount pump in vise. Placing Puller in vise will keep shaft of pump from turning while removing pulley and help keep tension on Puller and pulley hub.
    4.  
    5. Tighten Puller and remove pulley from shaft of power steering pump.
      NOTE
      Inspect pulley. Replace if pulley is bent, cracked, or loose.



      Click image to see an enlarged view

      Fig. View of the puller (2) installed on the power steering pump pulley. Mount the puller with the pump (1) in the vise as shown

    6.  

  16.  

To install:


WARNING
Do not hammer on power steering pump pulley or pump shaft to install pulley. This action will damage pulley and power steering pump.

  1. If the pulley was removed, perform the following:
    1. Place power steering pump pulley squarely on end of power steering pump shaft.
    2.  
    3. Place Installation Spacer, Special Tool 6936, on top of pump pulley.
      NOTE
      Later build pumps (vehicles built on or after 1/3/05) feature a shaft with internal threads that are not as deep as earlier production, thus requiring a stack of washers, approximately 0.5 in. (13mm) thickness, placed over Spacer 6936, before mounting Installer C-4063C on the pump. To know if a replacement pump requires the stack of washers, measure the depth of the shaft hole. A later build pump will have a depth of 0.78 in. (20mm) while an earlier build pump will have a depth of 1.25 in. (32mm).



      Click image to see an enlarged view

      Fig. Place Installation Spacer (1), Special Tool 6936, on top of pump pulley (2)



      Click image to see an enlarged view

      Fig. Later build pumps have a shaft with internal threads that are not as deep as earlier production, thus requiring a stack of washers, approximately 0.5 in. (13mm) thickness (3), placed over Spacer 6936 (2), before mounting Installer C-4063C (1) on the pump

    4.  
    5. Thread Installer, Special Tool C-4063C, completely into internal threads of power steering pump shaft, then rotate Installer Nut down against Spacer on pump pulley.

      Click image to see an enlarged view

      Fig. Thread Installer (1), Special Tool C-4063C, completely into internal threads of power steering pump shaft, then rotate Installer Nut down against Spacer (2) on pump pulley

    6.  
    7. Ensuring that special tools and pulley remain aligned with pump shaft, tighten Installer Nut, forcing pulley onto power steering pump shaft until Spacer comes in contact with end of pump shaft. When Spacer is against shaft of power steering pump, Installer Nut will no longer rotate.
    8.  
    9. Remove special tools from power steering pump.
    10.  

  2.  
  3. Align the power steering pump with mounting holes on engine.
  4.  
  5. Install the three pump mounting bolts through access holes in pulley. Tighten the bolts to 21 ft. lbs. (28 Nm).
    NOTE
    Always use a NEW O-ring on the end of the pressure hose.

  6.  
  7. Lubricate NEW O-ring on end of pressure hose with clean power steering fluid.
  8.  
  9. Connect the pressure hose to the pump. Tighten pressure hose tube nut to 35 ft. lbs. (47 Nm).
  10.  
  11. Install the supply hose on the pump. Install clamp securing hose in place.
  12.  
  13. Install the serpentine drive belt.
  14.  
  15. Install the air cleaner housing and inlet tube.
  16.  
  17. Connect battery negative cable to battery post. It is important that this is performed properly.
  18.  
  19. Fill the power steering pump reservoir with fluid and perform pump initial operation procedure.
  20.  

 
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