engine

Crankshaft Position Sensor

for 2007 Ram 3500 5.9L I6 Cummins · 4WD

Difficulty

Easy

Time

1.2 h

Tools

Steps

✓Fact-checked. Built from OLP's spec database, then independently fact-checked line by line with every correction applied. Master-tech sign-off by Chris Hackleman is queued. Cross-check torque values against the factory manual, and stop if anything looks unsafe. How our data is made.

This procedure covers the removal and replacement of the crankshaft position sensor on the 5.9L Cummins diesel engine.

Warnings

⚠Allow engine to cool completely before starting work to avoid burns from hot components.

ℹ️The crankshaft position sensor is critical for engine operation. A faulty sensor will prevent the engine from starting or cause rough running.

ℹ️Avoid touching the sensor tip or allowing metal debris near the sensor to prevent damage or false readings.

Tools required

10mm socketEssential

Socket wrench or ratchetEssential

Extension (3-6 inch)

Small flathead screwdriver or pick tool

Shop towels or ragsEssential

Electrical contact cleaner

Flashlight or work lightEssential

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Parts

Crankshaft position sensor × 1 — Use OEM specification (Mopar 5080160AA or equivalent)

As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.

Preparation

Park vehicle on level ground and engage parking brake
Allow engine to cool completely if recently operated
Disconnect negative battery cable to prevent electrical issues
Gather all tools and new crankshaft position sensor

Procedure

1
Locate the crankshaft position sensor
On the passenger side of the engine, locate the crankshaft position sensor. On the 5.9L Cummins it is mounted low on the engine block near the gear (timing) housing area at the front, reading a target/tone wheel on the crankshaft. The sensor has a single electrical connector attached to it.
2
Disconnect the electrical connector
Press the release tab on the electrical connector and carefully pull it away from the crankshaft position sensor. If the connector is difficult to remove, gently wiggle it while pulling. Use a small flathead screwdriver to assist with the release tab if necessary.
3
Remove the sensor mounting bolt
Using a 10mm socket and ratchet with extension if needed, remove the single bolt securing the crankshaft position sensor to the engine block near the gear housing. Keep the bolt in a safe location for reinstallation or replacement.
4
Extract the sensor from the bell housing
Carefully pull the crankshaft position sensor straight out of its mounting bore in the block. If the sensor is stuck due to corrosion or debris, gently twist while pulling. Avoid using excessive force that could break the sensor body and leave fragments in the hole.
5
Inspect the mounting hole and clean if necessary
Examine the sensor mounting hole for debris, metal shavings, or corrosion. Clean the area with a shop towel. Ensure no debris will interfere with the new sensor installation or sensor operation. Check the O-ring groove for damage.
6
Prepare the new sensor
Inspect the new crankshaft position sensor for any shipping damage. Verify the new sensor matches the old one in appearance and connector type. Check that the O-ring is properly seated on the new sensor body. Do not touch the sensor tip.
7
Install the new sensor
Carefully insert the new crankshaft position sensor into the mounting bore, ensuring it is fully seated against the mounting boss. The sensor should slide in smoothly without forcing. Align the sensor bolt hole with the threaded hole in the block.
8
Install and tighten the mounting bolt
Thread the 10mm (M6) mounting bolt by hand to avoid cross-threading. Torque the bolt to approximately 18 N·m (13 ft-lbs) using a torque wrench. Do not over-torque, as the sensor housing can crack.
9
Reconnect the electrical connector
Push the electrical connector onto the crankshaft position sensor until you hear or feel a positive click, indicating the locking tab has engaged. Gently tug on the connector to verify it is securely attached and will not come loose.
10
Reconnect the battery
Reconnect the negative battery cable to the battery terminal. Ensure the connection is tight and secure.

Reassembly

Ensure all electrical connections are secure and properly locked
Verify the sensor mounting bolt is tight
Double-check that no tools or parts were left in the engine compartment

Verification

Turn the ignition key to the ON position without starting the engine and verify no warning lights remain illuminated
Start the engine and verify it starts normally without extended cranking or rough running
Allow the engine to idle and confirm smooth operation with no misfires or irregular running
Use a scan tool if available to verify no crankshaft position sensor codes are present
Test drive the vehicle to ensure normal acceleration and operation under load