Oil Pump

This procedure covers removal and replacement of the oil pump on a 2007 Ram 3500 with 5.9L Cummins diesel engine, requiring removal of the oil pan and pickup tube to access the gear-driven oil pump.

Warnings

Tools required

Parts

• Oil pump assembly (gear-type) × 1 — Use OEM Cummins specification
• Oil pump gasket/O-ring kit × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Oil pickup tube O-ring × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification if replacing

Fluids

• 15W-40 diesel oil or 5W-40 synthetic — 12 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect both battery cables, negative first
3. Raise front of vehicle and support securely on jack stands at frame rails
4. Remove engine skid plate if equipped
5. Allow engine oil to warm slightly for easier draining, then let cool to safe working temperature
6. Place drain pan under engine oil pan

Procedure

1. 1

   Drain engine oil and remove filter
   Remove the oil drain plug from the oil pan and drain all engine oil into the drain pan. This will take several minutes due to the large oil capacity (approximately 12 quarts with filter — verify against factory specification). Once fully drained, remove the oil filter using the oil filter wrench. Reinstall the drain plug hand-tight for now to prevent debris entry.
2. 2

   Remove oil pan bolts and lower pan
   Remove all oil pan mounting bolts working from the outside edges toward the center. There are approximately 20-24 bolts securing the oil pan. Note that some bolts may be different lengths. Once all bolts are removed, carefully break the gasket seal using a pry bar at the designated pry points (typically at the corners). Lower the oil pan carefully, watching for any residual oil.
3. 3

   Remove oil pickup tube
   Remove the bolts securing the oil pickup tube to the oil pump and the support bracket bolted to the main bearing cap. Remove the pickup tube assembly and inspect the O-ring. Set aside the pickup tube for cleaning and O-ring replacement.
4. 4

   Access and inspect oil pump mounting
   Locate the oil pump located in the front gear cover/housing area of the engine block, driven by the crankshaft gear through the gear train. Remove the oil pump mounting bolts. The pump is a gerotor-type driven by the crankshaft gear. Consult the factory service manual for the exact pump location and bolt count on this Cummins engine. Inspect for any unusual wear patterns or damage to surrounding components.
5. 5

   Remove oil pump from crankshaft
   Carefully remove the oil pump assembly from the front of the engine, disengaging the pump driven gear from the crankshaft gear. If the pump is stuck, use gentle prying at the mounting flange, being careful not to damage the engine block surface. Do not force or twist the pump during removal. Consult the factory service manual for the correct removal procedure for the Cummins gerotor oil pump.
6. 6

   Clean all mating surfaces
   Thoroughly clean the engine block mounting surface for the oil pump using a gasket scraper and razor blade. Remove all old gasket material and RTV sealant. Clean the oil pan rail surfaces on the block completely, removing all old gasket material. Use brake cleaner to remove any oil residue. Inspect the crankshaft gear for wear or damage. Clean the pickup tube thoroughly and inspect the screen for debris.
7. 7

   Prepare and install new oil pump
   Install new O-ring or gasket on the new oil pump according to manufacturer instructions. Apply a thin coat of clean engine oil to the pump gears. Verify the crankshaft gear is clean and undamaged. Carefully align the new oil pump so its driven gear meshes properly with the crankshaft gear, ensuring proper engagement. Install the oil pump mounting bolts finger-tight, then torque to specification in a crisscross pattern per the factory service manual. Install the oil pump mounting bolts finger-tight, then torque to specification in a crisscross pattern. Note: Torque specifications not available in database - consult factory service manual.
8. 8

   Install oil pickup tube
   Install new O-ring on the oil pickup tube inlet. Apply a light coat of engine oil to the O-ring. Install the pickup tube to the oil pump and support bracket. Install mounting bolts finger-tight, then torque to specification. Ensure the pickup tube screen is positioned correctly in relation to the oil pan depth. Note: Torque specifications not available in database - consult factory service manual.
9. 9

   Install oil pan with new gasket
   Install the new oil pan gasket according to manufacturer instructions. Some gaskets use RTV sealant at corner joints while others are one-piece designs. If using RTV, apply a continuous 1/8-inch bead at the front and rear main seal retainer joints. Position the oil pan carefully onto the block, ensuring the gasket remains properly seated. Install all oil pan bolts finger-tight.
10. 10

    Torque oil pan bolts
    Torque the oil pan bolts in a crisscross pattern from the center outward. Start at the center bolts and work toward the ends and sides to ensure even gasket compression. Note: Torque specifications not available in database - consult factory service manual for proper sequence and torque values. Do not overtighten as this can warp the oil pan flange and cause leaks.
11. 11

    Reinstall drain plug and oil filter
    Remove the drain plug temporarily installed earlier, ensure the drain plug washer is in good condition (replace if necessary), and reinstall the drain plug torquing to specification. Install a new oil filter after lubricating the filter gasket with clean engine oil. Hand-tighten the filter to specification (typically 3/4 turn after gasket contact).
12. 12

    Reinstall skid plate and lower vehicle
    If equipped, reinstall the engine skid plate with all mounting hardware. Double-check that all drain plugs, filters, and pan bolts are properly installed and tightened. Carefully lower the vehicle from the jack stands.
13. 13

    Fill with engine oil
    Fill the engine with approximately 12 quarts of 15W-40 diesel oil or 5W-40 synthetic diesel oil as specified, verifying capacity against the factory service manual and filling to the dipstick full mark. Use the dipstick to verify proper oil level. Do not overfill.
14. 14

    Prime oil system and check for leaks
    Reconnect battery cables (positive first, then negative last). Note: the oil pump is mechanically driven and will not prime with the key in the run position. To pre-prime after an oil pump replacement, crank the engine in short bursts (fuel shutoff disabled if possible) or follow the factory service manual priming procedure until oil pressure registers before running the engine. Turn the ignition key to the run position without starting to allow the oil pump to prime. Start the engine and immediately check for oil pressure on the gauge. Monitor for any oil leaks around the oil pan, oil pump, and oil filter. Let the engine idle for several minutes while monitoring.

Reassembly

1. Torque all fasteners to factory specifications using a factory service manual as torque values were not available in the database
2. Ensure the oil pump gear is fully seated on the crankshaft before installing mounting bolts
3. Apply RTV sealant sparingly only where specified to avoid excess sealant entering oil passages
4. Allow RTV sealant to cure for the time specified by the manufacturer before filling with oil if applicable

Verification

• Start engine and verify oil pressure builds immediately on the gauge (should be 10+ psi at idle when warm, 30+ psi at operating RPM)
• Check for oil leaks at the oil pan gasket, oil pump mounting area, pickup tube, drain plug, and oil filter
• Allow engine to reach operating temperature and recheck oil level, adding oil if necessary
• Test drive vehicle and recheck for leaks and proper oil pressure under load
• After 100 miles, recheck oil level and inspect for any seepage at gasket surfaces

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