Power Steering Pump

This procedure covers removal and replacement of the power steering pump on a 1994-2007 Dodge Ram 2500 with 5.9L Cummins diesel engine, including serpentine belt removal, pulley transfer, and system bleeding.

Warnings

Tools required

Parts

• Power steering pump assembly × 1 — Remanufactured or new pump for 5.9L Cummins
• Power steering O-ring kit × 1 — High pressure and pressure line O-rings
• Serpentine belt × 1 — Replace if worn or contaminated

Fluids

• Mopar ATF+4 — 2.5 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Allow engine to cool if recently operated
3. Disconnect negative battery cable to prevent accidental starter engagement
4. Remove power steering reservoir cap to relieve any pressure
5. Use vacuum pump or turkey baster to remove as much fluid as possible from power steering reservoir
6. Position drain pan under power steering pump area

Procedure

1. 1

   Remove serpentine belt
   Locate the serpentine belt tensioner on the front of the engine. Using a serpentine belt tool or 1/2" breaker bar, rotate the tensioner in the direction that relieves belt tension (verify direction on the specific engine layout) to relieve belt tension. Slide the belt off the power steering pump pulley first, then release tensioner and remove belt from remaining pulleys. Inspect belt for wear, cracks, or fluid contamination and replace if necessary.
2. 2

   Disconnect high pressure hose
   Locate the high pressure hose fitting on the rear of the power steering pump. Position drain pan to catch fluid. Using an appropriately sized line wrench (verify fitting size), loosen and remove the high pressure hose fitting from the pump. Allow fluid to drain into pan. Cap or plug the hose end to prevent further fluid loss and contamination.
3. 3

   Disconnect pressure line fitting
   Using appropriate wrench, disconnect the pressure line fitting from the pump body. This is typically located on the pump housing near the high pressure hose connection. Allow remaining fluid to drain. Remove and discard old O-rings from both the high pressure hose and pressure line fittings using a pick or O-ring tool.
4. 4

   Disconnect return hose
   Locate the return hose on the power steering pump (typically a larger diameter low-pressure hose with a clamp). Loosen the hose clamp and slide it back on the hose. Carefully twist and pull the return hose off the pump fitting. Allow any remaining fluid to drain into the pan.
5. 5

   Remove pump mounting bolts
   Locate the power steering pump mounting bolts securing the pump to the engine bracket. There are typically 2-3 bolts depending on configuration. Using appropriate socket, remove all mounting bolts while supporting the pump. Note the location and length of each bolt for proper reinstallation.
6. 6

   Remove pump assembly
   Carefully maneuver the power steering pump out of the engine bay. The Cummins engine compartment is tight, so you may need to tilt or angle the pump to clear surrounding components. Once removed, place pump on clean work surface.
7. 7

   Transfer pulley to new pump
   Hold the pulley on the old pump using a pin spanner wrench inserted into the pulley holes. Using appropriate socket, remove the pulley nut. Remove pulley from old pump shaft. Inspect pulley for wear or damage. Install pulley onto new pump shaft, ensuring proper seating. Hold pulley with pin spanner and tighten pulley nut to specification.
   ⚠Pulley must be securely held with pin spanner to prevent shaft rotation and potential damage to pump internals.
   Torque spec

   Pulley Nut70 Nm (52 lb-ft)
8. 8

   Install new O-rings
   Install new O-rings onto the high pressure hose fitting and pressure line fitting. Lightly lubricate O-rings with clean power steering fluid (the same fluid used in the system) to ensure proper seating and prevent damage during installation. Ensure O-rings are properly seated in their grooves without twisting or pinching.
9. 9

   Install new pump
   Carefully position the new power steering pump into the mounting location, maneuvering around surrounding components. Align pump with mounting bracket holes. Install mounting bolts hand-tight, then torque to specification in a cross-pattern if multiple bolts are used.
   ℹ️Ensure pump is properly aligned before tightening bolts to prevent binding or misalignment.
   Torque spec

   Power Steering Pump Bolts25 Nm (18 lb-ft)
10. 10

    Connect pressure fittings
    Connect the pressure line fitting to the pump and hand-tighten. Torque to specification. Connect the high pressure hose fitting to the pump, ensuring the new O-ring is not damaged during installation. Hand-tighten first, then torque to specification using a line wrench to prevent rounding of fitting.
    ⚠Do not over-tighten fittings as this can damage O-rings and cause leaks. Use torque wrench for proper specification.
    Torque spec

    Pressure Line Fitting30 Nm (22 lb-ft)

    High Pressure Hose Fitting25 Nm (18 lb-ft)
11. 11

    Connect return hose
    Slide the return hose onto the pump fitting, ensuring it is fully seated. Position the hose clamp over the hose and fitting connection area. Tighten the clamp to specification, ensuring hose is secure but not over-compressed.
    Torque spec

    Return Hose Clamp3 Nm (2 lb-ft)
12. 12

    Install serpentine belt
    Route the new or inspected serpentine belt around all pulleys except the power steering pump pulley, following the belt routing diagram (typically found on the fan shroud or radiator support). Using belt tool or breaker bar, rotate tensioner in the tension-relieving direction (verify direction on the specific engine) and slip belt onto power steering pump pulley. Slowly release tensioner to apply proper tension. Verify belt is properly seated in all pulley grooves.
13. 13

    Fill and bleed power steering system
    Fill power steering reservoir with the manufacturer-specified power steering fluid (verify correct spec — many Cummins applications use Mopar Power Steering Fluid rather than ATF+4) to the cold fill line. Start engine and allow to idle. Turn steering wheel slowly from lock to lock 10-15 times without holding at full lock. Check fluid level and add as needed. Continue turning wheel lock to lock until no air bubbles appear in reservoir and fluid level stabilizes. Top off to proper cold level.
    ⚠Do not hold steering wheel at full lock for more than 5 seconds as this can overheat the pump and fluid.
    ℹ️Air in the system will cause noise and reduced assist. Complete bleeding is critical for proper operation.

Reassembly

1. Reconnect negative battery cable
2. Check all fittings and connections for leaks with engine running
3. Wipe down any spilled fluid from engine components and frame
4. Verify serpentine belt is tracking properly on all pulleys

Verification

• Start engine and verify power steering pump operates quietly without whining, groaning, or grinding noises
• Turn steering wheel lock to lock while stationary and verify smooth, consistent assist with no binding or cavitation noise
• Check power steering fluid level with engine at operating temperature and verify it is at the hot fill line
• Inspect all hose connections, pressure fittings, and pump mounting area for any signs of fluid leakage
• Test drive vehicle and verify steering assist functions properly at all speeds and during parking maneuvers
• Recheck fluid level after test drive and top off if necessary

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