Ram B1500, B2500, B3500, 1999-2003

Camshaft, Bearings & Lifters

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Inspection



  1. Mount the camshaft on v-blocks and check run-out. Max allowable in 0.001 in. (0.00004 mm).
  2.  
  3. Check for obvious signs of wear or damage, such as pitting or bluing of the lobes or bearings. Bluing, indicating heat damage, often damages the hardened surfaces, resulting in rapid wear. Imperfect camshafts should be replaced.
  4.  
  5. Check diameters of cam journals and bearing surfaces on the engine against the specifications given. Replace bearing inserts if not within specification.
  6.  



Click image to see an enlarged view

Fig. Camshaft lobe and bearing measuring points

Camshaft
Lobe Lift
3.9L, 5.2L, 5.9L Engines

NOTE
Check the lift of each lobe in consecutive order and make a note of the reading.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the valve cover(s).
  6.  
  7. Remove the intake manifold.
  8.  
  9. Remove the rocker arm stud nut or fulcrum bolts, fulcrum seat and rocker arm.
  10.  
  11. Make sure the pushrod is in the valve tappet socket. Install a dial indicator so that the actuating point of the indicator is in the push rod socket (or the indicator ball socket adapter is on the end of the pushrod) and in the same plane as the pushrod movement.
  12.  
  13. Disconnect the I terminal and the S terminal at the starter relay. Install an auxiliary starter switch between the battery and S terminals of the start relay.
  14.  
  15. Crank the engine with the ignition switch off. Turn the crankshaft over until the tappet is on the base circle of the camshaft lobe. At this position, the push rod will be in its lowest position.
  16.  
  17. Zero the dial indicator. Continue to rotate the crankshaft slowly until the push rod is in the fully raised position.
  18.  
  19. Compare the total lift recorded on the dial indicator with the specification shown on the Camshaft Specification chart.
  20.  
  21. To check the accuracy of the original indicator reading, continue to rotate the crankshaft until the indicator reads zero. If the left on any lobe is below specified wear limits listed, the camshaft and the valve lifter operating on the worn lobe(s) must be replaced.
  22.  
  23. Remove the dial indicator and auxiliary starter switch.
  24.  
  25. Install the rocker arm, fulcrum seat and stud nut or fulcrum bolts. Check the valve clearance. Adjust if required.
  26.  
  27. Install the intake manifold.
  28.  
  29. Install the valve cover(s).
  30.  
  31. Install the engine cover.
  32.  
  33. Connect the negative battery cable.
  34.  

Camshaft & Bearings
Bearings
  1. Remove the engine.
  2.  
  3. Remove the camshaft, flywheel and crankshaft.
  4.  
  5. Push the pistons to the top of the cylinder.
  6.  
  7. Remove the camshaft rear bearing bore plug.
  8.  
  9. Remove the camshaft bearings with a bearing removal tool. Select the proper size expanding collet and back-up nut and assemble on the mandrel. With the expanding collet collapsed, install the collet assembly in the camshaft bearing and tighten the back-up nut on the expanding mandrel until the collet fits the camshaft bearing.
  10.  
  11. Assemble the puller screw and extension (if necessary) and install on the expanding mandrel. Wrap a cloth around the threads of the puller screw to protect the front bearing or journal.
  12.  
  13. Tighten the pulling nut against the thrust bearing and pulling plate to remove the camshaft bearing. Be sure to hold a wrench on the end of the puller screw to prevent it from turning.
  14.  



Click image to see an enlarged view

Fig. Removal/installation of the camshaft bearings using a bearing installer/remover tool kit

  1. To remove the front bearing, install the puller from the rear of the cylinder block.
  2.  

To install:

  1. Position the new bearings at the bearing bores, and press them in place. Be sure to center the pulling plate and puller screw to avoid damage to the bearing. Failure to use the correct expanding collet can cause severe bearing damage. Align the oil holes in the bearings with the oil holes in the cylinder block before pressing bearings into place.
  2.  
  3. Install the camshaft rear bearing bore plug.
  4.  
  5. Install the camshaft, crankshaft, flywheel and related parts.
  6.  
  7. Install the engine.
  8.  

Camshafts & Tappets
  1. Refer to the camshaft section for OHV engines under "Engine Block", following.
  2.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Recover the A/C refrigerant, if equipped.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Negative battery cables
     
    Accessory drive belt and tensioner
     
    Cooling fan and shroud
     
    Radiator
     
    A/C condenser, if equipped
     
    Intercooler
     
    Auxiliary transmission cooler
     
    Upper radiator support
     
    Exhaust Gas Recirculation (EGR) tube
     
    Engine appearance cover
     
    Valve cover
     



    Rocker arms
     
    Pushrods
     
    Crankshaft pulley
     
    Front cover
     
    Lift pump
     

  8.  
  9. Insert dowel tools into the tappets. Raise the dowels and secure them with rubber bands.

    Click image to see an enlarged view

    Fig. Use dowel tools and rubber bands to hold the lifters up in the bore while removing the camshaft-5.9L diesel engine

  10.  
  11. Unbolt the thrust plate and remove the camshaft.
  12.  
  13. Install Cummins Tappet Changing Tool 3822513 into the camshaft bore.
  14.  
  15. Remove the dowel tools and remove the tappets. If the tappets are to be reused, note their locations for assembly.
  16.  

To install:

Click image to see an enlarged view

Fig. Tappet installation tools-5.9L diesel engine

  1. Insert the tappet installation tool into the pushrod bore. Use the tappet trough to pull the installation tool to the front of the engine block.
  2.  
  3. Attach a tappet to the installation tool and pull the tappet through the camshaft bore and into position in the tappet bore.
  4.  
  5. Rotate the trough so that the round side holds the tappet up in the tappet bore.
  6.  
  7. Remove the tappet installation tool and install a dowel tool to hold the tappet in place.
  8.  
  9. Repeat for each tappet to be installed.
  10.  
  11. Install or connect the following:

    Camshaft and thrust plate. Align the timing marks and tighten the bolts to 18 ft. lbs. (24 Nm).

    Click image to see an enlarged view

    Fig. Timing gear alignment marks-5.9L diesel engine

     
    Lift pump
     
    Front cover
     
    Crankshaft pulley. Tighten the bolt to 92 ft. lbs. (125 Nm).
     
    Pushrods
     
    Rocker arms
     
    Valve cover
     
    Engine appearance cover
     
    EGR tube
     
    Upper radiator support
     
    Auxiliary transmission cooler
     
    Intercooler
     
    A/C condenser, if equipped
     
    Radiator
     
    Cooling fan and shroud
     
    Accessory drive belt tensioner
     
    Accessory drive belt
     
    Negative battery cables
     

  12.  
  13. Fill the cooling system.
  14.  
  15. Start the engine and check for leaks.
  16.  

2.5L, 3.9L, 5.2L, 5.9L, & 8.0L
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fan, shrouds and radiator.
  4.  
  5. Unbolt the A/C compressor and place it aside.
  6.  
  7. Remove the intake manifold.
  8.  
  9. Remove the valve covers.
  10.  
  11. Remove and label the rocker arms and pivots.
  12.  
  13. Remove and label the pushrods.
  14.  
  15. On 2.5L engines, remove the tappets.
  16.  
  17. On other models,
    1. Remove the yoke retainer and label the aligning yokes for each cylinder, keeping them in order to ensure installation in their original locations.
    2.  

  18.  



Click image to see an enlarged view

Fig. Exploded view of a set of tappets (lifters), aligning yoke, and yoke retainer-5.9L engine shown



Click image to see an enlarged view

Fig. Remove the bolts that hold the yoke retainer to the engine block-5.2 engine shown



Click image to see an enlarged view

Fig. Lift the yoke retainer off of the engine block



Click image to see an enlarged view

Fig. Remove the aligning yoke for each lifter you are servicing, noting its location

  1. Slide a hydraulic valve tappet remover/installer into the bore and remove each lifter keeping them in order to ensure the installation in their original locations.
  2.  
  3. If the lifter or bore in the cylinder block is scored, ream the bore to the next oversize and replace with oversize lifters.
  4.  



Click image to see an enlarged view

Fig. Inspect the lifter for wear after removing; also inspect the bore for wear



Click image to see an enlarged view

Fig. The camshaft, as seen through the top of the engine block

  1. Remove the vibration damper, timing case cover, and timing chain and sprockets.
  2.  
  3. Remove the distributor and lift out the oil pump and distributor driveshaft. Mark position first to ease reassembly.
  4.  



Click image to see an enlarged view

Fig. The distributor drive gear is located in the distributor bore and is driven by the camshaft; the distributor must first be removed in order to access the drive gear

  1. Remove the camshaft thrust plate, if fitted.
  2.  
  3. On the 2.5L engine, remove the camshaft.
  4.  
  5. On "V" engines, install a long bolt into the front of the camshaft and remove the cam with caution.
  6.  



Click image to see an enlarged view

Fig. The camshaft thrust plate is located on the front of the engine block, under the timing chain camshaft sprocket

  1. See camshaft bearing section if replacing camshaft and bearings.
  2.  

To install:

  1. If a new camshaft is fitted, all the tappets should be replaced as well.
  2.  
  3. Prior to installation, lubricate the camshaft lobes and bearings journals. It is recommended that 1 pt. of Crankcase Conditioner be added to the initial crankcase oil fill.
  4.  
  5. Insert the camshaft into the engine block within 2 in. (51mm) of its final position in the block.
  6.  
  7. Have an assistant support the camshaft with a suitable tool to prevent the camshaft from contacting the plug in the rear of the engine block.
  8.  
  9. Position the suitable tool against the rear side of the cam gear and be careful not to damage the cam lobes.
  10.  
  11. Replace the camshaft thrust plate, if fitted. If camshaft end-play exceeds 0.010 in. (0.254mm), install a new thrust plate. It should be 0.002-0.006 in. (0.051-0.152mm) with the new plate.
  12.  
  13. Install the timing chain and sprockets, timing gear cover, vibration damper, and pulley.
  14.  
  15. To install the lifters:
    1. Lubricate the lifters.
    2.  
    3. Install the lifters in their original locations if installing the old ones.
    4.  
    5. Ensure that the oil feed hole in the side of the lifter faces up (away from the crankshaft).
    6.  
    7. Install the yokes and yoke retainer. Tighten the bolts to 200 inch lbs. (23 Nm).
    8.  

  16.  
  17. The remainder of the procedure is the reverse of removal.
  18.  

3.7L & 4.7L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Negative battery cable
     
    Cylinder head covers
     
    Rocker arms
     
    Hydraulic lash adjusters
     

  4.  
  5. Set the engine at Top Dead Center (TDC) of the compression stroke for the No. 1 cylinder.
  6.  
  7. Install Timing Chain Wedge (8350 4.7L; 8379 3.7L) to retain the chain tensioners.

    Click image to see an enlarged view

    Fig. Chain Tensioner Retaining Wedges-3.7L and 4.7L engines

  8.  
  9. Matchmark the timing chains to the camshaft sprockets.
  10.  
  11. Install Camshaft Holding Tool (6958 and Adapter Pins 8346 4.7L; 8428 3.7L) to the left camshaft sprocket.
  12.  
  13. On 3.7L engines, use tool 8428 and rotate the camshaft 5 degrees clockwise to eliminate valve load.
  14.  
  15. On 4.7L engines, use adjustable pliers to rotate the left camshaft 15 degrees clockwise to eliminate valve load. Use adjustable pliers to rotate the right camshaft 45 degrees counterclockwise to eliminate valve load.
  16.  
  17. Remove or disconnect the following:

    Right camshaft timing sprocket and target wheel
     
    Left camshaft sprocket
     
    Camshaft bearing caps, by reversing the tightening sequence
     
    Camshafts

    Click image to see an enlarged view

    Fig. Hold the left camshaft sprocket with a spanner wrench while removing or installing the camshaft sprocket bolts-4.7L engine



    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt tightening sequence-3.7L



    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt tightening sequence-4.7L engine

     

  18.  

To install:

  1. Install or connect the following:

    Camshafts. Torque the bearing cap bolts in 1 / 2 turn increments, in sequence, to 100 inch lbs. (11 Nm).
     
    Target wheel to the right camshaft
     
    Camshaft timing sprockets and chains, by aligning the matchmarks
     

  2.  
  3. Remove the tensioner wedges and tighten the camshaft sprocket bolts to 90 ft. lbs. (122 Nm).
  4.  
  5. Install or connect the following:

    Hydraulic lash adjusters in their original locations
     
    Rocker arms in their original locations
     
    Cylinder head covers
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Turn the camshaft with pliers, if needed, to align the dowel in the sprocket-4.7L engine

     

  6.  

3.9L, 5.2L & 5.9L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Recover the A/C refrigerant, if equipped with air conditioning.
  6.  
  7. Set the crankshaft to Top Dead Center (TDC) of the compression stroke for the No. 1 cylinder.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Negative battery cable
     
    Accessory drive belt
     
    Power steering pump
     
    Water pump
     
    Radiator
     
    A/C condenser
     
    Grille
     
    Crankshaft damper
     
    Front cover
     
    Valve covers
     
    Distributor
     
    Intake manifold
     



    Rocker arms and pushrods
     
    Hydraulic lifters
     
    Timing chain and sprockets
     
    Camshaft thrust plate and chain oil tab
     
    Camshaft

    Click image to see an enlarged view

    Fig. Camshaft holding tool C-3509-3.9L, 5.2L and 5.9L engines

     

  10.  

To install:

  1. Install or connect the following:

    Camshaft
     
    Camshaft Holding Tool C-3509
     
    Camshaft thrust plate and chain oil tab. Tighten the bolts to 18 ft. lbs. (24 Nm).
     
    Timing chain and sprockets. Tighten the camshaft sprocket bolt to 50 ft. lbs. (68 Nm).
     

  2.  
  3. Remove the camshaft holding tool.
  4.  
  5. Install or connect the following:

    Hydraulic lifters in their original positions
     
    Rocker arms and pushrods in their original positions
     
    Intake manifold
     
    Distributor
     
    Valve covers
     
    Front cover
     
    Crankshaft damper
     
    Grille
     
    A/C condenser
     
    Radiator
     
    Water pump
     
    Power steering pump
     
    Accessory drive belt
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Recharge the A/C system, if equipped.
  10.  
  11. Start the engine and check for leaks.
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Recover the A/C refrigerant, if equipped with air conditioning.
  6.  
  7. Set the crankshaft to Top Dead Center (TDC) of the compression stroke for the No. 1 cylinder.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Negative battery cable
     
    Accessory drive belt
     
    Power steering pump
     
    Water pump
     
    Radiator
     
    A/C condenser
     
    Grille
     
    Crankshaft damper
     
    Front cover
     
    Valve covers
     
    Distributor
     
    Intake manifold
     



    Rocker arms and pushrods
     
    Hydraulic lifters
     
    Timing chain and sprockets
     
    Camshaft thrust plate and chain oil tab
     
    Camshaft

    Click image to see an enlarged view

    Fig. Camshaft holding tool C-3509-3.9L, 5.2L and 5.9L engines

     

  10.  

To install:

  1. Install or connect the following:

    Camshaft
     
    Camshaft Holding Tool C-3509
     
    Camshaft thrust plate and chain oil tab. Tighten the bolts to 18 ft. lbs. (24 Nm).
     
    Timing chain and sprockets. Tighten the camshaft sprocket bolt to 50 ft. lbs. (68 Nm).
     

  2.  
  3. Remove the camshaft holding tool.
  4.  
  5. Install or connect the following:

    Hydraulic lifters in their original positions
     
    Rocker arms and pushrods in their original positions
     
    Intake manifold
     
    Distributor
     
    Valve covers
     
    Front cover
     
    Crankshaft damper
     
    Grille
     
    A/C condenser
     
    Radiator
     
    Water pump
     
    Power steering pump
     
    Accessory drive belt
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Recharge the A/C system, if equipped.
  10.  
  11. Start the engine and check for leaks.
  12.  

4.7L Engine

WARNING
Cams can be removed after the cylinder head covers are taken off if special tool 8350 (timing chain wedge) is available. If not, removal of the timing chain cover is required in order to reset chain tensioners.

  1. Remove the cylinder head covers.
  2.  
  3. alilgn the crankshaft damper mark with the TDC mark on the cover and both cam sprocket V8 marks to the 12 o'clock position.
  4.  
  5. Mark secondary timing chains relative to the sprocket.
  6.  
  7. Loosen, but Do NOT remove, the cam sprocket bolts.
  8.  
  9. Use timing chain wedge 8350 between the timing chain strands to keep the tensioners from extending when the sprocket are removed.
  10.  
  11. Remove the sprocket. See procedures above.
  12.  
  13. Starting at the ends of the cam and working inward, loosen the cam bearing cap bolts 1 / 2 turn at a time until loose.
  14.  
  15. Mark the rocker arms for position.
  16.  
  17. Remove the cam bearing caps and camshaft.
  18.  



Click image to see an enlarged view

Fig. Cam bearing bolt tightening sequence-4.7L engine

To install:

  1. Lube all parts with clean engine oil.
  2.  
  3. Install the left side camshaft so the sprocket dowel is near the 1 o'clock position.
  4.  
  5. Tighten the bearing cap bolts in 1 / 2 turn increments, starting in the middle and working out (see illustration). Final torque in 100 inch lbs. (11 Nm).
  6.  
  7. Assemble and install the timing chain sprocket assembly as outlined in the relevant section.
  8.  

5.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Recover the A/C refrigerant, if equipped with air conditioning.
  6.  
  7. Set the crankshaft to Top Dead Center (TDC) of the compression stroke for the No. 1 cylinder.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Camshaft rear cam bearing core plug
     
    Air cleaner
     
    Accessory drive belt
     
    Alternator
     
    A/C compressor
     
    Radiator
     
    Intake manifold
     
    Cylinder head covers
     
    Cylinder heads
     
    Oil pan
     
    Front cover
     
    Oil pickup tube
     
    Oil pump
     
    Timing chain and sprockets
     
    Camshaft thrust plate
     
    Hydraulic lifters
     
    Camshaft
     

  10.  

To install:

  1. Install or connect the following:
    NOTE
    Lifters must be replaced in their original positions.



    Camshaft
     
    Camshaft thrust plate. Tighten the bolts to 21 ft. lbs. (28 Nm).
     
    Timing chain and sprockets
     
    Oil pump
     
    Oil pickup tube
     



    Hydraulic lifters
     
    Cylinder heads
     
    Pushrods
     
    Rocker arms
     
    Front cover
     
    Oil pan
     
    Cylinder head covers
     
    Intake manifold
     
    A/C compressor
     
    Alternator
     
    Accessory drive belt
     
    Radiator
     
    Air cleaner
     
    Camshaft rear cam bearing core plug
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Recharge the A/C system, if equipped.
  6.  
  7. Start the engine and check for leaks.
  8.  

8.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Recover the A/C refrigerant, if equipped with air conditioning.
  4.  
  5. Drain the cooling system.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Negative battery cable
     
    Valve covers
     
    Upper and lower intake manifolds
     



    Rocker arms
     
    Pushrods
     
    Cylinder heads
     
    Valve lifters
     
    Crankshaft pulley
     
    Front cover
     
    Timing chain and sprockets
     
    Camshaft thrust plate
     
    Camshaft
     

  10.  

To install:

  1. Install or connect the following:

    Camshaft
     
    Camshaft thrust plate
     
    Timing chain and sprockets. Tighten the bolt to 55 ft. lbs. (75 Nm).
     
    Front cover
     
    Crankshaft pulley
     
    Valve lifters
     
    Cylinder heads
     
    Pushrods
     
    Rocker arms
     
    Upper and lower intake manifolds
     
    Valve covers
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Recharge the A/C system, if equipped.
  6.  
  7. Start the engine and check for leaks.
  8.  

Diesel Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the cylinder head covers.
  4.  
  5. Remove the rocker pedestal and arm assemblies.
  6.  
  7. Remove the pushrods.
  8.  
  9. Remove the drive belt.
  10.  
  11. Drain the cooling system. Remove the fan assembly, radiator and all related parts.
  12.  
  13. Remove the crankshaft pulley.
  14.  
  15. Remove the front gear cover.
  16.  
  17. Remove the fuel pump.
  18.  
  19. Insert the special dowels into the pushrod holes and onto the top of each lifter. When properly installed, the dowels can be used to hold the tappets up securely. Wrap rubber bands around the top of the dowels to prevent them from dropping down.
  20.  



Click image to see an enlarged view

Fig. Insert the tappet dowels to hold the tappets up securely-diesel engine

  1. Rotate the crankshaft to align the crankshaft to camshaft timing marks.
  2.  



Click image to see an enlarged view

Fig. Align the crankshaft to the camshaft on the diesel engine as shown

  1. Remove the bolts from the thrust plate.
  2.  



Click image to see an enlarged view

Fig. Insert the thrust plate bolts on the diesel engine in the location shown

  1. Remove the camshaft and thrust plate.
  2.  
  3. Press the gear from the camshaft and remove the key.
  4.  

To install:

  1. Install the key on the camshaft.
  2.  
  3. Heat the camshaft gear to 250-F (121-C) for 45 minutes. Lubricate the gear mount surface with Lubriplate 105®. Install the gear to the camshaft with the timing marks facing away from the shaft.
  4.  
  5. Lubricate the camshaft bores, lobes, journals and thrust washer with Lubriplate 105®.
  6.  


NOTE
Do NOT push the camshaft in too far or it may dislodge the plug in the rear of the camshaft bore, possibly creating a leak.

  1. Install the camshaft and thrust washer so the "E" timing mark on the injection pump gear aligns with the "C" timing mark on the camshaft gear and the timing mark on the crankshaft gear align with those on the camshaft gear.
  2.  
  3. Install the thrust washer bolts and tighten to 18 ft. lbs. (24 Nm).
  4.  
  5. Check the endplay of the camshaft. The specification is 0.006-0.010 in. (0.152-0.254mm).
  6.  
  7. Check the backlash of the camshaft gear. The specification is 0.003-0.013 in. (0.080-0.330mm).
  8.  
  9. Install the tappets and pushrods.
  10.  
  11. Install the rocker pedestal and arm assemblies.
  12.  
  13. Install the front cover and crankshaft pulley.
  14.  
  15. Install the drive belt and fan assembly.
  16.  
  17. Install the fuel pump.
  18.  
  19. Adjust the valves.
  20.  
  21. Install the cylinder head covers.
  22.  
  23. Connect the negative battery cable and check for leaks.
  24.