Power Steering Pump

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

Warnings

Tools required

Parts

• Power steering pump × 1 — Use OEM specification
• Pressure line O-rings × 2 — Use OEM specification
• Serpentine belt (if damaged or worn) × 1 — Use OEM specification

Fluids

• ATF+4 power steering fluid — 2.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely
3. Disconnect negative battery cable
4. Place drain pan under power steering pump area
5. Inspect serpentine belt for wear, cracks, or damage and replace if necessary

Procedure

1. 1

   Remove serpentine belt
   Using a 1/2 inch breaker bar or serpentine belt tool, rotate the belt tensioner clockwise to relieve tension. Rotate the belt tensioner to relieve tension and slip the belt off the pulleys. Note: the Cummins power steering pump is gear-driven and is not on the serpentine belt, so belt removal may not be required for pump replacement. Carefully release tensioner and remove belt from engine bay. Note belt routing for reinstallation.
2. 2

   Drain power steering fluid
   Disconnect the return hose at the pump (or the remote reservoir return line, whichever is accessible and lower) by loosening the hose clamp. Allow fluid to drain completely into the drain pan. Use shop towels to catch any remaining fluid. Cap or plug the return hose to prevent additional drainage.
3. 3

   Disconnect pressure line
   Using a line wrench, carefully loosen the pressure line fitting at the pump. Locate the fitting on the pump body per the service manual (access is tight on the Cummins). Once loosened, unthread completely and move line away from pump. Cap the line to prevent contamination. Discard the old sealing O-ring(s) from the fitting; verify the correct quantity and type against the service manual before reassembly.
   ⚠Use a line wrench to prevent rounding off the pressure line fitting
4. 4

   Remove power steering pump mounting bolts
   Remove the power steering pump mounting bolts (verify count against the service manual) that secure the gear-driven pump to the front gear housing/mounting bracket. Support the pump while removing the final bolt to prevent it from falling.
5. 5

   Remove power steering pump
   Carefully maneuver the power steering pump out of the engine bay. The pump may need to be tilted or rotated to clear surrounding components; note that the Cummins pump is gear-driven off the front gear housing. Be careful not to spill remaining fluid on engine components or the ground.
6. 6

   Prepare new power steering pump
   Remove shipping caps from new pump. Verify the new pump matches the old pump in configuration and port locations. Install new O-rings on the pressure line fitting, lightly lubricating them with clean ATF+4 fluid. Do not over-lubricate.
7. 7

   Install new power steering pump
   Position the new power steering pump into the mounting bracket, aligning the mounting bolt holes. Thread in all three mounting bolts by hand first to ensure proper alignment. Once all bolts are started, tighten them in a cross pattern to specification using a torque wrench.
   Torque spec

   Power Steering Pump Bolts25 Nm (18 lb-ft)
8. 8

   Connect pressure line
   Remove cap from pressure line. Thread the pressure line fitting into the pump by hand until it seats. Using a line wrench and torque wrench, tighten the fitting to specification. Ensure the O-rings are properly seated and not pinched.
   ⚠Do not over-tighten the pressure line fitting as this can damage the O-rings and cause leaks
   Torque spec

   Pressure Line Fitting30 Nm (22 lb-ft)
9. 9

   Connect return hose
   Reconnect the return hose to the power steering pump. Position the hose clamp properly and tighten to specification. Ensure the hose is fully seated on the pump nipple.
   Torque spec

   Return Line Clamp4 Nm (3 lb-ft)
10. 10

    Install serpentine belt
    Route the serpentine belt according to the belt routing diagram (usually found on the fan shroud or radiator support). Install the belt on all pulleys except the power steering pump pulley. Rotate the tensioner to relieve tension and slip the belt onto the last pulley, then release the tensioner. Note: the Cummins power steering pump is gear-driven and is not on the belt path. Verify the belt is properly seated in all pulley grooves.
11. 11

    Fill and bleed power steering system
    Fill the power steering reservoir to the cold fill line with the fluid specified in the service manual (ATF+4 for most 2007 Ram applications — verify). Start the engine and turn the steering wheel slowly from lock to lock 10-15 times while the engine idles. Check fluid level frequently and add as needed. Continue until no air bubbles appear in the reservoir and the fluid level stabilizes. Avoid holding the steering wheel at full lock for extended periods to prevent pump damage.
    ⚠Do not hold steering wheel at full lock for more than 5 seconds to avoid damaging the pump

Reassembly

1. Reconnect negative battery cable
2. Remove fender covers and clean any spilled fluid from painted surfaces immediately
3. Dispose of old power steering fluid according to local regulations

Verification

• Check power steering fluid level with engine at normal operating temperature and verify it is at the hot fill line
• Inspect all connections for leaks, particularly the pressure line fitting and return hose
• Test steering operation at idle and while driving to ensure proper assist and no unusual noises
• Verify serpentine belt is properly tensioned and not slipping on pulleys
• Recheck fluid level after test drive and top off if necessary

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