Power Steering Hose - Return

This procedure involves removing and replacing the power steering return hose on a 1994-2007 Dodge Ram 2500 with the 5.9L Cummins diesel engine, including system drainage, hose routing, and fluid refill with air bleeding.

Warnings

Tools required

Parts

• Power steering return hose × 1 — Use OEM specification
• Hose clamps (if not integrated with hose) × 2 — Worm-gear style, appropriate diameter
• Power steering reservoir cap/filter screen × 1 — Inspect and replace if damaged

Fluids

• Mopar ATF+4 — 2.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Allow engine to cool completely if recently driven
3. Place wheel chocks behind rear wheels for additional safety
4. Raise front of vehicle and secure on jack stands if additional underside access is needed
5. Place large drain pan under power steering reservoir and pump area
6. Have shop rags ready to contain fluid spillage during disconnection

Procedure

1. 1

   Drain power steering reservoir
   Remove the power steering reservoir cap. Use a turkey baster or fluid transfer pump to remove as much fluid as possible from the reservoir. This minimizes spillage when disconnecting the return hose. Dispose of old fluid properly.
2. 2

   Locate and access return hose
   The power steering return hose runs from the bottom/side of the power steering reservoir to the power steering pump. On the Cummins diesel, access from the driver's side of the engine bay. The return hose is the larger diameter, low-pressure hose compared to the smaller high-pressure line. Trace the hose routing and identify any clips or mounting points securing it.
3. 3

   Disconnect return hose at reservoir
   Position drain pan directly under the reservoir connection. Using hose clamp pliers or a flathead screwdriver, loosen the hose clamp securing the return hose to the reservoir outlet fitting. Slide the clamp back along the hose away from the connection point. Twist and pull the hose off the reservoir fitting. Be prepared for residual fluid to drain out. Plug the reservoir outlet with a clean rag if needed to prevent further drainage.
4. 4

   Disconnect return hose at power steering pump
   Reposition drain pan under the power steering pump area. Loosen the hose clamp at the pump return fitting using the same method. The return fitting is typically on the lower side or rear of the pump body. Twist and pull the hose off the pump fitting. Allow remaining fluid to drain into the pan. Inspect the pump return fitting for damage or debris.
5. 5

   Remove old hose and inspect routing
   Release any routing clips or ties securing the return hose along its path. Remove the old hose completely from the vehicle. Inspect the routing path for any sharp edges, heat sources, or contact points that could damage the new hose. Clean the reservoir outlet fitting and pump return fitting with a shop rag to remove any old fluid residue or debris.
6. 6

   Install new return hose at pump
   Position new hose clamp on the new return hose at the pump end. Route the new hose following the original path, ensuring it does not contact hot exhaust components, sharp edges, or moving parts. Slide the hose onto the power steering pump return fitting until it bottoms out (typically 1.5-2 inches onto the barbed fitting). Position the hose clamp 1/4 inch from the end of the hose and tighten securely. Ensure the clamp is beyond the barbed section of the fitting.
7. 7

   Install new return hose at reservoir
   Position new hose clamp on the reservoir end of the return hose. Route the hose upward to the reservoir outlet, maintaining proper clearances from all engine components. Slide the hose onto the reservoir outlet fitting until it bottoms out. Position the hose clamp 1/4 inch from the end of the hose and tighten securely. Verify the hose has no kinks, sharp bends, or contact points along its entire length.
8. 8

   Secure hose routing
   Reinstall any factory routing clips or ties to secure the return hose in its proper position. Ensure the hose maintains at least 1 inch clearance from exhaust manifolds, turbocharger components, and the serpentine belt. The hose should have slight slack to accommodate engine movement without strain on the connections.
9. 9

   Fill power steering system
   Using the fluid specified for your model year (Mopar power steering fluid or, for later model years, the manufacturer-specified fluid — verify against the service manual), fill the power steering reservoir to the FULL COLD mark on the dipstick or reservoir side. Do not overfill. Install the reservoir cap loosely. Start the engine and let it idle. The fluid level will drop as the system fills. Stop the engine and add fluid to bring it back to the FULL COLD mark. Repeat this process until the fluid level stabilizes.
10. 10

    Bleed air from system
    With the engine off, turn the steering wheel slowly from lock to lock (full left to full right) 10-15 times. This helps purge air from the system. Check fluid level and top off as needed. Start the engine and let it idle. Turn the steering wheel slowly from lock to lock 5-10 times while idling. Check for smooth operation without noise. Stop the engine and check fluid level one final time, topping off to FULL COLD mark if needed.
11. 11

    Inspect for leaks and test system
    With the engine idling, carefully inspect both hose connections at the reservoir and pump for any signs of leakage. Check along the entire hose length for seepage. Turn the steering wheel through its full range several times and recheck all connections. If any leaks are present, stop the engine, tighten the affected hose clamp, and retest. Verify power steering operates smoothly without noise, binding, or cavitation sounds.

Reassembly

1. Lower vehicle from jack stands if raised
2. Wipe down all components in the work area to remove any spilled power steering fluid
3. Verify reservoir cap is installed securely
4. Check fluid level one final time after vehicle has been test driven and is at operating temperature

Verification

• Power steering fluid level is at the appropriate mark on the dipstick (FULL COLD when cold, FULL HOT when warm)
• No fluid leaks visible at either hose connection point or along the hose length
• Power steering operates smoothly and quietly through full range of motion in both directions
• No whining, groaning, or cavitation noises from the power steering pump during operation
• Return hose has proper clearance from all hot and moving components
• Hose clamps are tight and properly positioned on both connections

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