Washer Reservoir

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

Warnings

Tools required

Parts

• Washer reservoir assembly × 1 — Use OEM specification
• Washer pump (if damaged) × 1 — Use OEM specification

Fluids

• Windshield washer fluid — 4.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Allow engine to cool completely if recently operated
3. Open hood and secure with prop rod
4. Place drain pan under driver's side of vehicle near front wheel to catch any spilled washer fluid

Procedure

1. 1

   Drain washer fluid
   Disconnect the washer pump electrical connector by pressing the release tab and pulling straight out. Disconnect the washer hose from the pump outlet by squeezing the retaining clip and pulling the hose off. Allow remaining fluid to drain into the drain pan.
2. 2

   Remove inner fender liner access panel (if equipped)
   Remove the plastic push clips securing the front portion of the driver's side inner fender liner to access the reservoir mounting bolts. This may require turning the front wheels to the right for better access. Use a panel removal tool or flathead screwdriver to carefully release the clips without breaking them.
3. 3

   Remove air intake components
   On the Cummins diesel, the air intake routing may partially obstruct access to the reservoir. Loosen the clamp on the intake tube at the air filter housing and move the tube aside for better access. Do not fully remove unless necessary.
4. 4

   Disconnect washer pump wiring
   If not already disconnected, locate the washer pump electrical connector on the bottom of the reservoir and press the locking tab to disconnect it. Note the routing of the wiring harness for reinstallation.
5. 5

   Remove mounting fasteners
   Remove the reservoir mounting bolts using a 10mm socket. There are typically two mounting bolts securing the reservoir to the inner fender well. Support the reservoir with one hand while removing the final fastener.
6. 6

   Remove reservoir from vehicle
   Carefully maneuver the reservoir up and out of the engine bay. The reservoir neck may be tight against surrounding components. Tilt and rotate as needed to clear the battery, air intake, and fender well. Any remaining fluid will drain out during removal.
7. 7

   Transfer washer pump if reusing
   If the washer pump is functioning properly and only the reservoir needs replacement, remove the pump from the old reservoir by rotating it counterclockwise approximately 1/4 turn and pulling out. The pump has a rubber grommet seal that should come out with it. Inspect the grommet for cracks or damage and replace if necessary.
8. 8

   Install washer pump in new reservoir
   Insert the washer pump with grommet into the new reservoir opening. Align the tabs and rotate clockwise 1/4 turn until it locks into place. Ensure the pump is fully seated and the grommet creates a watertight seal.
9. 9

   Install new reservoir
   Maneuver the new reservoir into position in the driver's side fender well, reversing the removal process. Ensure the mounting holes align with the threaded inserts in the fender. Install and hand-tighten the mounting bolts, then snug them down with a 10mm socket. Do not overtighten as you are threading into plastic.
10. 10

    Reconnect hoses and wiring
    Connect the washer hose to the pump outlet, ensuring the retaining clip snaps into place. Reconnect the electrical connector to the washer pump until it clicks. Route the wiring harness as originally positioned.
11. 11

    Reinstall air intake and fender liner
    Reposition the air intake tube if it was moved and tighten the clamp securely. Reinstall any inner fender liner push clips that were removed, ensuring they are fully seated.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify all mounting bolts are snug but not overtightened
3. Confirm washer hose is securely connected with retaining clip engaged
4. Double-check that no tools or parts were left in the engine bay

Verification

• Fill the reservoir with approximately 4.5 quarts of windshield washer fluid to the full line
• Turn ignition to ON position without starting engine
• Activate the windshield washer function and verify fluid sprays from both nozzles
• Check for leaks around the pump grommet seal and hose connections
• Inspect the mounting area to ensure no fluid is leaking from the reservoir
• Verify the low washer fluid warning light (if equipped) illuminates when fluid is below minimum level and extinguishes when filled

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