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Author Topic: Power Steering Pump Replacement  (Read 21259 times)

Offline FroneDaddy

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Power Steering Pump Replacement
« on: March 25, 2010, 04:06:34 pm »
PS pump replacement on an ’03 Ram 2500 5.9l Diesel.

First step is to remove the serpentine belt. The tensioner is located between the crank and the A/C compressor. This picture is from the bottom looking up.



From underneath the truck using a 3/4 drive ratchet on the ‘tighten’ setting put pressure on the tensioner and slip the belt off of the A/C compressor. Now you can remove the entire belt from the motor from up top under the hood.

Next, remove both rubber lines from the PS cooler and let it drain. The cooler is located at the bottom of the radiator and right in front of it.



After the fluid drains for a few mins have someone hold those 2 lines and point them into a container and bump the starter a few times to get the remaining fluid out. If you don’t have someone hold the lines the fluid will shoot straight out and make a big mess all over the ground.

There is a bracket bolted to the block and there are 3 bolts that hold the PS pump to the bracket, and there are holes in the pulley itself to access the bolts. To remove the bolts holding the pump to the bracket you need to rotate the pulley and line the holes up with a bolt and put your ratchet through the pulley to access the bolts. This is done easiest from underneath the truck. Do not remove the high pressure line from the pump yet.

MAKE SURE YOUR IGNITION IS OFF AS YOUR HANDS WILL BE IN THE FAN WHILE REMOVING THESE BOLTS!!

In this pic you can see the 3 bolts sticking through the back of the bracket and the high pressure line on the left.



Next you have to remove your top radiator line and tie it out of the way, your throttle cable cover (if you have one), your intake horn & intercooler tube.



One thing I forgot to take a picture of is coming off the bottom of the reservoir is a tube. About 6 inches down that tube there is a ‘T.’ If you remove your driver’s side fenderwell you can access that ‘T’ very easily. You will see the large tube coming off the reservoir, another large tube on the other side of the ‘T’ that goes to the cooler and a smaller line at the bottom of the ‘T,” remove the hose clamp on the bottom smaller line and disconnect it.

The PS pump, pulley & reservoir all have to be removed from the top of the engine compartment. It takes some patience & maneuvering but it does come out.

Once you get the assembly to the top of the engine compartment, you will need two wrenches to remove the high pressure line. If you don’t use two you may end up loosening the fitting from the pump itself. If that happens some internals may fall out or move around and you run the risk of not getting your core back.



Now take the whole assembly to your bench and you should have something that looks like this.



Put the pump in a vice and use a PS pump pulley puller to remove the pulley (assuming your new pump didn’t come with a pulley).







Next, if your new pump didn’t come with a reservoir you need to remove it from your old pump, transfer the bracket to the new one and mount the reservoir. You need to do this before pressing the pulley on the new pump as there’s no room to access one of the screws once the pulley is on.



Use your pulley tool again to press the pulley on the new pump. It should now look like this.



To re-install, lay the assembly on top of the motor and reconnect the high pressure line but don’t make it tight as you’ll need to rotate the line a little bit. Slide the pump onto the bracket and install the 3 bolts. Access through the pulley is a real PAIN but it can be done.

Once the pump is all bolted up tighten down the high pressure line.



Now reconnect the cooler lines and the line that goes into the ‘T’ through the wheel well. Since your serpentine belt is off you may as well check it for dry rot and cracks and replace as needed. Install the belt, there should be a diagram above your radiator, if not put the ribbed side of the belt on the grooved pulleys and the back side on the smooth pulleys. Re-install the intake horn, radiator hose, throttle cable cover, intercooler tube and all clamps.

Jack the front of the truck up and support with jack stands. Turn your wheels to the left and fill the PS reservoir with approx 3/4 quart of ATF+4.

DO NOT USE POWER STEERING FLUID!!

Start the truck up and turn the wheels side to side several times then let the truck run for a few minutes. Check the fluid again, it should take approx. another 1/4 quart or a little more. Start the truck again and continue turning the wheel several more times and check the fluid and add as needed. Lower to the ground and you should be good to go.

The wheel may feel tight for a short period as there may still be a little air still in the system that should work itself out over a few short trips.
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Offline spencea15

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Re: Power Steering Pump Replacement
« Reply #1 on: March 25, 2010, 04:34:12 pm »
Nice job frone. 
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Offline Cumminalong

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Re: Power Steering Pump Replacement
« Reply #2 on: March 25, 2010, 05:00:34 pm »
Very Nice!

:up:

Offline Cujo

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Re: Power Steering Pump Replacement
« Reply #3 on: March 25, 2010, 05:27:44 pm »
Nice job Anthony.  :up:
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Offline Kilch123

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Re: Power Steering Pump Replacement
« Reply #4 on: March 28, 2010, 03:24:59 am »
Nice Job Anthony!

I hope you don't have to go thru it again...
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Offline FroneDaddy

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Re: Power Steering Pump Replacement
« Reply #5 on: March 28, 2010, 10:58:23 pm »
Yea, tell me about it! It appears that way though :suicide:
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Offline 04cumminsram

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Re: Power Steering Pump Replacement
« Reply #6 on: March 29, 2010, 02:08:24 am »
good job man !
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