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

Removal & Installation

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WARNING
Do not attempt to remove the pump without removing the belt first. The automatic tensioner is under a high spring load.

  1. Remove drive belt by rotating tensioner clockwise and sliding belt off tensioner pulley.
  2.  
  3. Disconnect hoses from the power steering pump and cap fittings.
  4.  
  5. Remove bracket bolts and remove pump assembly.

    Click image to see an enlarged view

    Fig. Exploded view of the power steering pump assembly (1) and mounting bolts (2)

    Exploded view of the power steering pump assembly (1) and mounting bolts (2)
  6.  
  7. Remove the pump pulley from pump with Puller C-4333, or equivalent puller. Replace the pulley if it is bent, cracked or loose.

    Click image to see an enlarged view

    Fig. Use a suitable puller (2) to remove the pulley from the pump

    Use a suitable puller (2) to remove the pulley from the pump
  8.  
  9. Remove pump bracket, if equipped.

    Click image to see an enlarged view

    Fig. Exploded view of the power steering pump and related components including the bracket, 3.9L only (1), nut (2), screw (3), steering pump (4), pulley (5), and screw (6)

    Exploded view of the power steering pump and related components including the bracket, 3.9L only (1), nut (2), screw (3), steering pump (4), pulley (5), and screw (6)
  10.  

To install:

  1. Install pump bracket to pump and tighten the bolts to:
    1. 3.9L & 5.2L engine: 40 ft. lbs. (54 Nm).
    2.  
    3. 5.9L engine: 21 ft. lbs. (28 Nm).
    4.  

  2.  
  3. Install the pump pulley on the pump with Installer C-4063-B flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft.

    Click image to see an enlarged view

    Fig. Install the pump pulley (1) on the pump with Installer C-4063-B (2) flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft

    Install the pump pulley (1) on the pump with Installer C-4063-B (2) flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft
  4.  
  5. Install pump assembly on engine block and tighten bolts to 30 ft. lbs. (41 Nm).
  6.  
  7. Connect hoses to pump and tighten fitting to 25 ft. lbs. (35 Nm).
  8.  
  9. Install the serpentine belt. Run engine until warm (about 5 minutes) and note any belt chirp. If chirp exists, move pulley outward approximately 0.020 in. (0.5mm). If noise increases, press on 0.040 in. (1.0mm). Be careful that pulley does not contact mounting bolts.

    Click image to see an enlarged view

    Fig. Accessory serpentine belt routing-A/C compressor (1), Without A/C (2), Power Steering Pump (3), Water Pump (4), Crankshaft Pulley (5), Auto tensioner (6), Alternator (7), Idler pulley (8)

    Accessory serpentine belt routing-A/C compressor (1), Without A/C (2), Power Steering Pump (3), Water Pump (4), Crankshaft Pulley (5), Auto tensioner (6), Alternator (7), Idler pulley (8)
  10.  
  11. Fill pump reservoir with power steering fluid only, refer to Pump Initial Operation.
  12.  

Diesel Engines



  1. Remove and cap steering pump hoses and vacuum pump vacuum line.
  2.  
  3. Remove the sender unit from engine block and plug hole in block.
  4.  
  5. Remove the serpentine belt, as outlined in the Engine Mechanical Section.
  6.  
  7. Remove and cap the oil feed line from the bottom of the vacuum pump.
  8.  
  9. Remove the lower bolt that attaches the vacuum/steering pump assembly to the engine block. Remove the nut from the steering pump attaching bracket.
  10.  
  11. Remove upper bolt from the pump assembly and remove the assembly.
  12.  
  13. Remove the mounting gasket.
  14.  
  15. Remove the steering pump to vacuum pump bracket attaching nuts.
  16.  
  17. Slide the steering pump from the bracket. Use care not to damage the internal oil seal in the vacuum pump.
  18.  
  19. Remove the two pump body spacers.
  20.  

To install:

  1. Install the two pump body spacers.
  2.  
  3. Rotate the drive gear until the steering pump and vacuum pump drive dogs align. Install the steering pump onto the vacuum pump bracket. Use care to avoid damaging the oil seal in the vacuum pump during installation. The steering pump housing and spacers must mate completely with the vacuum pump bracket.
  4.  
  5. Install the vacuum pump bracket to steering pump nuts and tighten to 18 ft. lbs. (24 Nm).
  6.  
  7. Position new gasket on vacuum pump assembly. Use sealer if necessary to retain the gasket.
  8.  
  9. Align and install the pump assembly on the engine. Ensure the steering pump stud is inserted into the block bracket. Tighten the pump- to-engine block attaching bolts to 57 ft. lbs. (77 Nm).
  10.  
  11. Install the steering pump to attaching bracket nut and tighten to 18 ft. lbs. (24 Nm).
  12.  
  13. Remove plug and install the oil pressure sending unit and electrical connector.
  14.  
  15. Install the oil feed line to the vacuum pump. Tighten the oil line connection to 60 inch lbs. (7 Nm).
  16.  
  17. Install the fluid hoses to the power steering pump. Tighten the pressure fitting at the pump to 23 ft. lbs. (31 Nm).
  18.  
  19. Install and clamp the hose on the vacuum pump.
  20.  
  21. Install the serpentine belt.
  22.  
  23. Fill the reservoir with power steering fluid and perform the -Initial Operation Procedure-, located later in this section.
  24.  
  25. Start the engine and check the operation of the brakes.
  26.  

  1. Drain and siphon the power steering fluid from the reservoir.
  2.  
  3. Remove the serpentine belt, as outlined in the Engine Mechanical Section.
    WARNING
    Do not remove the fitting on the pump that the high pressure hose screws into. The fitting may come loose unless it is backed up using another wrench. If the fitting does come loose, it must be retightened to 40-50 ft. lbs. (57-67 Nm) before continuing. If this fitting comes out of the pump body, the internal spring and valve parts will fall out of the pump and they cannot be reinstalled properly. If this occurs the pump needs to be replaced with a new pump.

  4.  
  5. Disconnect the return hose.
  6.  
  7. Disconnect the pressure hose.
  8.  
  9. Access to remove the three bolts securing the pump to the cylinder head can be gained thru the pulley holes.
  10.  
  11. Loosen the pump bracket to the block.
  12.  
  13. Remove the 6 intake plenum bolts.
  14.  
  15. Loosen the inner cooler tube clamp at the intake plenum and remove the intake plenum.
  16.  
  17. Loosen the inner cooler tube clamp at the radiator support side and remove the tube from the vehicle.
  18.  
  19. Remove the power steering pump from the top of the engine compartment where the intake plenum was.

    Click image to see an enlarged view

    Fig. View of the intake plenum (1) and power steering pump (2) mounting

    View of the intake plenum (1) and power steering pump (2) mounting
  20.  

To install:

  1. Set the power steering pump in place in the engine compartment from the top.
  2.  
  3. Install the inner cooler tube.
  4.  
  5. Tighten the inner cooler tube clamp at the radiator support side.
  6.  
  7. Install the 6 intake plenum bolts.
  8.  
  9. Tighten the inner cooler tube clamp at the intake plenum.
  10.  
  11. Install 3 pump mounting bolts through the pulley access holes. Tighten the bolts to 21 ft. lbs. (28 Nm).
  12.  
  13. Tighten the pump bracket to the block.
  14.  
  15. Reconnect the pressure line and return hose to the pump and reservoir. Tighten the pressure line to 27 ft. lbs. (37 Nm).
  16.  
  17. Install the serpentine drive belt.
  18.  
  19. Fill the reservoir with power steering fluid and perform the -Initial Operation Procedure-, located later in this section.
  20.  
  21. Start the engine and check the operation of the brakes.
  22.  

Gasoline Engines



  1. Remove the serpentine drive belt, as outlined in the Engine Mechanical Section.
  2.  
  3. Remove the hoses from the power steering pump and cap the fittings.
  4.  
  5. Remove battery ground cable and unthread stud from cylinder head, do not remove from bracket.
  6.  
  7. Loosen upper bracket bolt and remove the lower bracket to engine block bolts.
  8.  
  9. Pivot the pump assembly past the coolant tube.
  10.  
  11. Remove the upper stud and remove upper bolt from cylinder head.
  12.  
  13. Remove steering pump and mounting bracket from engine as an assembly.
  14.  
  15. Remove the pump pulley with Puller C-4333, to access pump attaching bolts.
  16.  
  17. Remove the front pump bracket. On the 8.0L engine remove rear pump bracket.
  18.  

To install:

  1. Install the front pump bracket and tighten bolts to35 ft. lbs. (47 Nm). On the 8.0L engine install the rear pump bracket and tighten nut to 35 ft. lbs. (47 Nm), tighten bolts to 18 ft. lbs. (24 Nm).
  2.  
  3. Install the pump pulley with Installer C-4063-B.
  4.  
  5. Install steering pump assembly on the engine block. Install the upper stud and bolt in bracket.
  6.  
  7. Pivot the pump down past the coolant tube and install the lower bolts in bracket.
  8.  
  9. Tighten the bolts and nut to 30 ft. lbs. (41 Nm).
  10.  
  11. Connect the hoses to the pump.
  12.  
  13. Install the serpentine drive belt.
  14.  
  15. Fill the reservoir with power steering fluid and perform the -Initial Operation Procedure-, located later in this section.
  16.  

  1. Drain and siphon the power steering fluid from the reservoir.
  2.  
  3. Remove the serpentine belt, as outlined in the Engine Mechanical Section.
    WARNING
    Do not remove the fitting on the pump that the high pressure hose screws into. The fitting may come loose unless it is backed up using another wrench. If the fitting does come loose, it must be retightened to 40-50 ft. lbs. (57-67 Nm) before continuing. If this fitting comes out of the pump body, the internal spring and valve parts will fall out of the pump and they cannot be reinstalled properly. If this occurs the pump needs to be replaced with a new pump.

  4.  
  5. Disconnect the return hose.
  6.  
  7. Disconnect the pressure hose.
  8.  
  9. Access to remove the three bolts securing the pump to the cylinder head can be gained thru the pulley holes.

    Click image to see an enlarged view

    Fig. View of the power steering pump pulley (1), fluid reservoir (2), return hose (3) and high pressure hose (4)

    View of the power steering pump pulley (1), fluid reservoir (2), return hose (3) and high pressure hose (4)
  10.  

To install:

  1. Align the pump with the mounting holes in the left cylinder head.
  2.  
  3. Install 3 pump mounting bolts through the pulley access holes. Tighten the bolts to 21 ft. lbs. (28 Nm).
  4.  
  5. Reconnect the pressure line and return hose to the pump and reservoir. Tighten the pressure line to 27 ft. lbs. (37 Nm).
  6.  
  7. Install the serpentine drive belt.
  8.  
  9. Fill the reservoir with power steering fluid and perform the -Initial Operation Procedure-, located later in this section.
  10.  
  11. Start the engine and check the operation of the brakes.
  12.  

 
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