2nd Gen Non-Engine/Transmission 1999 power steering pump replacement

[KPitcher]

I have a 1999 Dodge with a 24 valve Cummins diesel engine and I need to change the power steering pump. According to the 1999 Dodge service manual (p19-9) I need to remove the vacuum assembly with the pump attached. The pump is then unbolted from the vacuum assembly, replaced and the complete assembly is then reinstalled and bolted to the engine. The procedure also has instructions to remove a oil pressure sending unit close to the pump but my engine does not have an oil pressure sending unit mounted where the manual shows (Fig 4).

Question 1.

It appears easier to just remove the pump from the vacuum assembly (do not remove the vacuum assembly from the engine) and install a new pump instead of removing the pump/vacuum assembly to change the pump. The only caution is to make sure the oil seal in the vacuum assembly is not damaged during installation of the pump. Has anyone successfully changed a pump without removing the vacuum assembly?

Question 2.

I think the air inlet housing must be removed (p11-15) to allow enough room to remove the pump. The manual does not have you remove the air inlet housing. Has anyone successfully removed and installed a pump assembly without removing the air inlet housing?

Question3.

Does anyone know where the oil pressure sending unit is mounted on my engine?

 

[Ram4Sam]

I would remove the ps pump/vac pump as a unit, it is real easy. The chance of damaging the vac pump seal are good, and don't forget, the vac pump seal is probably ten years old and brittle, and probably should be replaced anyway. Removing the intercooler pipe and the battery gives you plenty of room.



Sam

 

[BDaugherty]

I've replaced several PS pumps by only removing the PS pump and leaving the vacuum pump attached. Getting the dog coupler lined back up is a PITA and every single one that I've done has ended up leaking between the PS and vacuum pumps. Granted, they were all 100k+ trucks, but still.

If it were me, I would pull the vacuum pump and PS pump as an assembly. Then I would install a new seal on both sides of the vacuum pump. After that, put the new PS pump back on and hook it back to the engine. You don't have to pull the inlet elbow, but it really does make it easier. Since it's your first time, just pull the elbow and pipe so you have plenty of room to work.

 

[Joe Mc]

Don't forget to bleed air out of the pump before thinking it's all good. Fill to cold level, have front wheels off the ground turn lock to lock several times, check & refill reservoir and repeat - checking the fluid until it stops dropping - drive for about 10 - 15 miles and check your level.

 

[KPitcher]

Sam and B Daugherty

I want to thank both of you for your inputs. I know you are both right but I was a little depressed after seeing where the pump was located and then reading that I had to remove a vacuum line, an oil line, two mounting bolts that look difficult to access and then remove the complete assembly. I plan on removing both the vacuum pump and steering pump. I will take the oil seal advice and replace both oil seals.

Thank you again,

Ken



Joe,

Thank you for your advice on filling and testing the system after installing the new pump.

Ken

 

[KPitcher]

Vacuum Pump Seal Replacement

I replaced the power steering pump and the seals in the vacuum pump and it appears to be successful. For others that have not replaced the seals in a vacuum pump I will briefly describe my experience.

My truck (1999 3500 dually) has cruse control and I had to remove the air intake housing and the air intake heater to have enough room to remove the vacuum pump/ power steering pump assembly. Even with the air intake and heater removed it was difficult to get the vacuum pump/ power steering pump assembly out and back in.

It took me 2 hours to remove the two hoses on the power steering pump. Using a small screwdriver, pliers and a heat gun I got them off but split about 1/2 inch on both hoses. Luckily the are both long enough that I was able to get them back on after cutting off 1/2 in. I just hope I did not damage them so they leak some time in the future.

I highly recommend purchasing the vacuum pump gasket kit from Geno’s Garage. The kit costs $59. 99 plus shipping. The kit comes with instructions, a DVD and 3 seal driver tools. After you watch the DVD it is very easy to change the seals.

I tried to install the vacuum pump/power steering pump assembly 3 times and the gasket between the vacuum pump and engine kept moving. I finally used some spray adhesive to stick the gasket to the vacuum pump and was finally able to install assembly. It takes 2 people to install the assembly. One person needs to be under the truck to tell the person installing the assembly how to move the assembly so the stud on the power steering pump goes through the bracket on the engine. I rigged up a small rope, part of a broom handle, and a C clamp for a lift to help me hold the assembly. I threaded the rope through the pump adapter and attached it to the handle with duct tape. With the assembly held in place the second person positioned the handle across the engine and twisted the handle until the rope was tight then tightened the C clamp on the handle to prevent the rope from unwinding. It took 2 tries to get the right height. The person then got under the truck and guided the stud through the bracket and started the nut on the stud. Because my vacuum pump has an oil feed fitting it was not necessary for me to start the oil feed line prior to bolting up the assembly as stated in the DVD.

I bleed the lines by raising the front wheels off the ground and turning the steering wheel from lock to lock 25 times while watching the fluid level.

Time will tell if I did a good job but no leaks on the initial test drive. I did have one problem when I started the engine the first time. Sometime during the removal or installation I moved the water drain lever on the fuel filter and had a major fuel leak when I started the engine. It is a good idea to check the position of the lever prior to starting the engine.

It took me about 8 hous from start to finish but I worked alone except for a little help on the installation.

 

[SGevers]

Thanks for the detailed experience. My vacuum pump seal kit has been sitting on my work bench a couple weeks now, first I have to replace my u-joints the I will tackle this while I am at it.