Power Steering Pump Pulley

This procedure covers the removal and installation of the power steering pump pulley on a 2007 Ram 3500 with 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Power steering pump pulley × 1 — Use OEM specification
• Serpentine belt (if damaged) × 1 — Use OEM specification

Fluids

• ATF+4 power steering fluid — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect both battery cables, negative first, then positive
3. Allow engine to cool completely if recently operated
4. Place drain pan under power steering pump area
5. Have new pulley and ATF+4 fluid ready for installation

Procedure

1. 1

   Remove serpentine belt
   Locate the serpentine belt tensioner on the front of the engine. Using a serpentine belt tool or appropriate wrench, rotate the tensioner in the direction that relieves belt tension (verify direction for this application) to release tension. Remove the belt from all pulleys, noting the routing path for reinstallation. If routing diagram is faded on the fan shroud, draw a diagram before removing.
2. 2

   Access power steering pump
   The power steering pump is mounted on the driver side of the engine block. Remove any components obstructing clear access to the pump pulley. On some configurations, the fan shroud may need to be loosened or repositioned for adequate working space.
3. 3

   Drain power steering fluid
   Position drain pan directly under the power steering pump. Using a turkey baster or fluid pump, remove as much fluid as possible from the power steering reservoir. Disconnect the return hose from the reservoir and allow remaining fluid to drain into the pan. Cap or plug the reservoir outlet to prevent further spillage.
4. 4

   Install pulley puller tool
   Install the power steering pump pulley puller so its jaws grip firmly behind the pulley face, then thread the puller's center bolt against the pump shaft end. Ensure the puller jaws grip firmly behind the pulley face. The tool must be centered and seated squarely to prevent damage to the pump shaft. Verify that the puller is not contacting the pump housing.
5. 5

   Remove pulley from pump
   Turn the center bolt of the pulley puller per the tool instructions to draw the pulley off the pump shaft. Apply steady, even pressure. The pulley should come off smoothly without excessive force. If significant resistance is encountered, stop and verify tool alignment. Remove the pulley and set aside. Inspect the pump shaft for any damage or scoring.
6. 6

   Inspect pump shaft and pulley
   Examine the power steering pump shaft for wear, scoring, or damage. Check the shaft end for burrs that could prevent proper pulley installation. Inspect the new pulley bore for cleanliness and any manufacturing debris. Verify the new pulley matches the old pulley design and dimensions exactly.
7. 7

   Position new pulley on shaft
   Clean the pump shaft with a shop towel to remove any residue. Align the new pulley with the pump shaft and slide it on by hand as far as possible. The pulley should slide on smoothly without binding. Do not force the pulley or hammer it into place, as this will damage the pump bearings.
8. 8

   Install pulley installer tool
   Assemble the power steering pulley installer tool according to manufacturer instructions. The tool consists of a threaded rod, thrust bearing, and pressing plate. Thread the installer into the pump shaft, position the pressing plate against the pulley face, and ensure everything is aligned squarely on the shaft.
9. 9

   Press pulley onto shaft
   Turn the installer tool bolt clockwise to press the pulley onto the shaft. Press the pulley until it is fully seated and flush with the end of the pump shaft. The pulley face should be at the correct depth to align with other serpentine belt pulleys. Do not over-press the pulley beyond the shaft end, as this can damage internal pump components.
10. 10

    Verify pulley alignment
    Remove the installer tool. Visually check that the pulley is seated completely and sits perpendicular to the pump shaft. Manually rotate the pulley to ensure it spins freely without wobble or binding. Check alignment with adjacent pulleys by placing a straight edge across the pulley faces.
11. 11

    Reinstall serpentine belt
    Route the serpentine belt around all pulleys following the diagram noted during removal or the routing diagram on the fan shroud. Ensure the belt ribs are properly seated in all pulley grooves. Use the belt tensioner tool to rotate the tensioner clockwise and slip the belt over the final pulley. Release tensioner slowly to apply proper tension.
12. 12

    Reconnect power steering lines
    Reconnect the power steering return hose to the reservoir and secure with the clamp. Wipe down any spilled fluid from surrounding components. Reinstall any components that were removed for access.
13. 13

    Refill and bleed power steering system
    Fill the power steering reservoir with the manufacturer-specified power steering fluid (verify ATF+4 vs. MOPAR power steering fluid per the owner's manual for this vehicle) to the FULL COLD mark. Reconnect battery cables, positive first then negative. Start the engine and turn the steering wheel slowly from lock to lock several times while checking fluid level. Add fluid as needed and continue until no air bubbles appear in the reservoir. Recheck fluid level with engine running and at operating temperature.

Reassembly

1. Ensure serpentine belt is properly routed and tensioned on all pulleys
2. Verify power steering reservoir is filled to proper level with ATF+4
3. Reinstall any fan shroud components or brackets removed for access
4. Check for any tools or parts left in engine compartment before closing hood

Verification

• Start engine and verify no unusual noises from power steering pump or pulley area
• Turn steering wheel from lock to lock multiple times and verify smooth operation without binding or noise
• Check for any power steering fluid leaks around pump, hoses, and reservoir
• Verify serpentine belt is tracking properly on all pulleys with engine running
• Recheck power steering fluid level after test drive and top off if necessary
• Inspect belt alignment and pulley operation after vehicle reaches operating temperature

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