Power Steering Hose - Return

Replace the power steering return hose on a 2007 Ram 3500 with 5.9L Cummins diesel engine, including fluid drain and refill procedures.

Warnings

Tools required

Parts

• Power steering return hose × 1 — Use OEM specification
• Hose clamps (if not included with hose) × 2 — Worm-drive style, appropriate diameter

Fluids

• ATF+4 — 3 qt

Preparation

1. Park vehicle on level ground and apply parking brake
2. Allow engine to cool if recently operated
3. Place wheel chocks behind rear wheels
4. Raise front of vehicle if additional clearance is needed for access (optional but helpful)
5. Place drain pan beneath power steering reservoir and along expected hose routing path
6. Remove power steering reservoir cap to allow venting during fluid drain

Procedure

1. 1

   Drain power steering reservoir
   Use a turkey baster or fluid pump to remove as much fluid as possible from the power steering reservoir. This minimizes spillage when disconnecting the return hose. Transfer drained fluid to your drain pan for proper disposal.
2. 2

   Locate return hose connections
   Trace the power steering return hose from the reservoir to the steering gear. On the 5.9L Cummins, the return hose connects to the bottom or side of the power steering reservoir and runs down to the steering gear mounted on the frame rail. The return line is typically smaller diameter than the pressure line and will not have reinforced braiding.
3. 3

   Disconnect hose from reservoir
   Position drain pan directly beneath the reservoir connection. Using hose clamp pliers or a screwdriver, loosen the clamp securing the return hose to the reservoir fitting. Slide the clamp back along the hose away from the connection point. Twist and pull the hose off the reservoir nipple. Allow fluid to drain into the pan.
4. 4

   Disconnect hose from steering gear
   Locate the return hose connection at the steering gear (typically on the driver side frame rail). Loosen the clamp at this connection and slide it back. Twist and pull the hose off the steering gear return port. Additional fluid will drain from both the hose and the gear; keep drain pan positioned to catch it.
5. 5

   Remove old hose from vehicle
   Trace the hose routing carefully and note any clips, brackets, or routing points that secure the hose. Remove the hose from any retaining clips along its path. Extract the old hose from the vehicle and inspect the routing for any areas of chafing or interference that may have caused premature failure.
6. 6

   Prepare new hose and fittings
   Compare the new return hose to the old one to verify correct length and end fittings. Clean the reservoir nipple and steering gear return port with a wire brush or shop rag to remove any old fluid residue or debris. Inspect both fittings for damage or corrosion. Position new clamps on the hose before installation if using worm-drive style clamps.
7. 7

   Install new return hose
   Route the new hose along the same path as the original, ensuring it does not contact hot exhaust components or moving parts. Push the hose firmly onto the steering gear return port first, ensuring it seats completely on the nipple. Then connect the other end to the power steering reservoir nipple, again ensuring full seating.
8. 8

   Secure hose clamps
   Position the clamp at the steering gear connection approximately 1/4 inch from the end of the hose and tighten securely. Repeat for the reservoir connection. If using spring clamps, ensure they are fully seated in their grooves. If using worm-drive clamps, tighten until snug but do not overtighten as this can cut into the hose.
9. 9

   Secure hose in retaining clips
   Install the return hose in all factory routing clips and brackets along its path. Ensure the hose has no kinks, sharp bends, or areas where it contacts the frame or other components. Leave slight slack to allow for engine movement.
10. 10

    Refill power steering system
    Fill the power steering reservoir with fresh Mopar power steering fluid (meeting Chrysler MS-5931/MS-9933) to the COLD or MIN mark on the dipstick. Do not overfill. Install the reservoir cap loosely to allow air to escape during the bleeding process.
11. 11

    Bleed air from system
    Turn the steering wheel fully from lock to lock (do not hold at full lock) approximately 20 times without starting the engine. This helps move fluid through the system and purge air. Check fluid level frequently and add Mopar power steering fluid (meeting Chrysler MS-5931/MS-9933) as needed. Start the engine and allow it to idle while turning the steering wheel slowly from lock to lock several times. Check for leaks at both hose connections.
12. 12

    Check fluid level and top off
    With engine at idle and fluid warmed to operating temperature, turn the steering wheel lock to lock a final time. Shut off the engine and check the fluid level. Top off to the HOT or MAX mark as needed with Mopar power steering fluid (meeting Chrysler MS-5931/MS-9933). Securely install the reservoir cap.

Reassembly

1. Lower vehicle if it was raised during service
2. Wipe down any spilled power steering fluid from components and frame
3. Verify all clamps are tight and hose is properly routed in all retaining clips
4. Dispose of used ATF+4 according to local regulations

Verification

• Start engine and verify no leaks at either hose connection point
• Turn steering wheel fully in both directions and confirm smooth operation without noise
• Check power steering fluid level with engine warm; level should be at HOT/MAX mark
• Verify no whining or groaning noise from power steering pump indicating air in system
• Inspect the ground beneath vehicle after a short test drive to confirm no fluid leaks
• Re-check all connections and fluid level after first 50 miles of driving

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle