Power Steering Reservoir

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

Warnings

Tools required

Parts

• Power steering reservoir × 1 — Use OEM specification
• Reservoir mounting grommet (if damaged) × 1 — Use OEM specification
• Hose clamps (if corroded) × 2 — Worm gear style, appropriate sizes

Fluids

• ATF+4 — 2.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Allow engine to cool completely if recently operated
3. Place drain pan under work area to catch fluid spills
4. Remove engine cover if equipped by lifting upward on retaining clips
5. Use turkey baster or fluid pump to remove as much fluid as possible from reservoir to minimize spillage

Procedure

1. 1

   Disconnect return hose from reservoir
   Locate the lower return hose on the reservoir. Using hose clamp pliers or flathead screwdriver, loosen the worm gear clamp securing the return hose to the reservoir nipple. Slide the clamp down the hose away from the reservoir. Twist and pull the hose off the reservoir nipple. Position the hose end into the drain pan to catch remaining fluid.
2. 2

   Disconnect supply hose from reservoir
   Locate the upper supply hose connection on the bottom of the reservoir. Loosen the hose clamp securing this hose to the reservoir. Twist and pull the hose off the reservoir. Have shop towels ready as fluid will drain from both the hose and reservoir. Position the hose end into the drain pan.
3. 3

   Remove reservoir mounting bracket bolt
   Locate the single 10mm mounting bolt securing the reservoir bracket to the firewall or inner fender. Using a 10mm socket and ratchet, remove this bolt completely. Keep the bolt for reinstallation.
4. 4

   Remove reservoir from mounting location
   Lift the reservoir upward and out of the mounting grommet. Tilt the reservoir to drain any remaining fluid into the drain pan. Inspect the mounting grommet on the firewall or bracket; if cracked or damaged, remove and replace it.
5. 5

   Inspect and prepare new reservoir
   Compare the new reservoir to the old unit to verify correct replacement part. Check that the inlet and outlet nipples are clean and free of debris. If the new reservoir includes a cap and filter screen, ensure the screen is properly seated inside the reservoir neck.
6. 6

   Install new reservoir
   Position the new reservoir into the mounting grommet, ensuring it seats fully and the hose connections face downward in the correct orientation. Align the mounting bracket hole with the threaded hole in the firewall or inner fender.
7. 7

   Install mounting bracket bolt
   Insert the 10mm mounting bolt through the reservoir bracket and thread it into the mounting point. Tighten the bolt securely by hand, then snug with the socket and ratchet. Do not overtighten as this can crack the plastic reservoir bracket.
8. 8

   Connect supply hose to reservoir
   Push the supply hose (upper connection) onto the bottom nipple of the reservoir until it is fully seated. Slide the hose clamp up to the connection point and tighten securely. Ensure the hose is not kinked or twisted.
9. 9

   Connect return hose to reservoir
   Push the return hose (lower connection) onto the appropriate reservoir nipple until fully seated. Slide the hose clamp into position over the connection and tighten securely. Verify both hoses are properly routed and not contacting hot engine components or sharp edges.
10. 10

    Fill reservoir with fresh ATF+4
    Remove the reservoir cap and fill the reservoir with fresh Mopar Power Steering Fluid +4 (or OEM-specified power steering fluid) to the cold fill line marked on the reservoir. Do not overfill. Replace the cap loosely for the bleeding process.
11. 11

    Bleed power steering system
    With the engine off, turn the steering wheel from lock to lock (full left to full right) approximately 10-15 times to purge air from the system. Check the fluid level frequently and add Mopar Power Steering Fluid +4 (or OEM-specified power steering fluid) as needed to maintain the cold fill level. Continue until no air bubbles are visible in the reservoir and the fluid level stabilizes.
12. 12

    Start engine and complete bleeding
    Start the engine and let it idle. Turn the steering wheel slowly from lock to lock 3-4 times while monitoring fluid level and checking for leaks at hose connections. Add Mopar Power Steering Fluid +4 (or OEM-specified power steering fluid) as necessary to maintain proper level. The fluid level should be at the hot fill line when the engine is at operating temperature. Tighten the reservoir cap securely when bleeding is complete.

Reassembly

1. Reinstall engine cover if removed by pressing down on mounting clips until seated
2. Inspect the area around the reservoir and hose connections for any fluid leaks
3. Wipe down the reservoir and surrounding area to remove any spilled fluid

Verification

• With engine running, verify no leaks at reservoir hose connections or mounting area
• Check that fluid level is at the appropriate mark (cold or hot depending on engine temperature)
• Turn steering wheel lock to lock and verify smooth operation with no whining or groaning noises
• Recheck fluid level after test drive and top off if necessary
• Verify reservoir cap is tight and no fluid is leaking from cap seal

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