2002 DODGE RAM power steering fluid

necessary. The initial pressure reading should be in
the range of 345-552 kPa (50-80 psi).
(6) Increase the engine speed to 1500 RPM and
read the flow meter. If the flow rate (GPM) is below
specification (Refer to pump specification chart for
GPM) the pump should be replaced.
CAUTION: The following test procedure involves
testing maximum pump pressure output and flow
control valve operation. Do not leave valve closed
for more than three seconds as the pump could be
damaged.
(7) Close valve fully three times and record high-
est pressure indicated each time.All three read-
ings must be above specifications and within
345 kPa (50 psi) of each other.
²Pressures above specifications but not within
345 kPa (50 psi) of each other, replace pump.
²Pressures within 345 kPa (50 psi) of each other
but below specifications, replace pump.
(8) Open the test valve and turn the steering
wheel to the extreme left and right positions three
times against the stops. Record the highest pressure
reading at each position. Compare the readings to
the pump specifications chart. If pressures readings
are not within 50 psi of each other, the gear is leak-
ing internally and must be repaired.CAUTION: Do not force the pump to operate against
the stops for more than 2 to 3 seconds at a time
because, pump damage will result.
PUMP SPECIFICATION
ENGINERELIEF PRESSURE
(P.S.I.)FLOW
(G.P.M.) at
1500 RPM
3.9L 1450 to 1550 2.7 to 3.1
5.2L 1450 to 1550 2.7 to 3.1
5.9L 1450 to 1550 2.7 to 3.1
8.0L 1450 to 1550 2.7 to 3.1
5.9L
Diesel1450 to 1550 3.1 to 3.5
All With
Hydraulic
Booster1450 to 1550 3.1 to 3.5
NOTE: After preforming test and removing Power
Steering Analyzer, check power steering fluid level.
BR/BESTEERING 19 - 5
STEERING (Continued)

(7) Remove spool valve O-ring and valve body
teflon rings and O-rings underneath the teflon rings
(Fig. 29).
(8) Remove the O-ring between the worm shaft
and the stub shaft.
INSTALLATION
NOTE: Clean and dry all components, then lubricate
with power steering fluid.
(1) Install spool valve spool O-ring.
(2) Install spool valve in valve body by pushing
and rotating. Hole in spool valve for stub shaft pin
must be accessible from opposite end of valve body.
(3) Install stub shaft in valve spool and engage
locating pin on stub shaft into spool valve hole (Fig.
30).
NOTE: Notch in stub shaft cap must fully engage
valve body pin and seat against valve body shoul-
der.
(4) Install O-rings and teflon rings over the
O-rings on valve body.
(5) Install O-ring into the back of the stub shaft
cap (Fig. 31).
(6) Install stub shaft and valve assembly in the
housing. Line up worm shaft to slots in the valve
assembly.
(7) Install thrust support assembly.
NOTE: The thrust support is serviced as an assem-
bly. If any component of the thrust support is dam-
aged the assembly must be replaced.
Fig. 28 Spool Valve
1 - SPOOL VALVE
2 - ROTATE VALVE TO REMOVE
3 - VALVE BODY
Fig. 29 Valve Seals
1 - O-RING SEALS
Fig. 30 Stub Shaft Installation
1 - NOTCH IN CAP
2 - VALVE BODY PIN
19 - 28 GEARBR/BE
SPOOL VALVE (Continued)

INSTALLATION
(1) Lubricate O-ring with power steering fluid and
install into the housing.
(2) Install end plug by tapping the plug lightly
with a plastic mallet into the housing.
(3) Install retaining ring so one end of the ring
covers the housing access hole (Fig. 34).
WORM SHAFT
REMOVAL
(1) Remove housing end plug, (Refer to 19 -
STEERING/GEAR/STEERING GEAR HOUSING
PLUG - REMOVAL).
(2) Remove rack piston plug (Fig. 35).
(3) Remove side cover and pitman shaft.
(4) Turn stub shaft COUNTERCLOCKWISE until
the rack piston begins to come out of the housing.
(5) Insert Arbor C-4175 into bore of rack piston
(Fig. 36) and hold tool tightly against worm shaft.
(6) Turn the stub shaft with a 12 point socket
COUNTERCLOCKWISE, this will force the rack pis-
ton onto the tool and hold the rack piston balls in
place.
(7) Remove the rack piston and tool together from
housing.
(8) Remove tool from rack piston.
(9) Remove rack piston balls.
(10) Remove clamp bolts, clamp and ball guide
(Fig. 37).
Fig. 34 Installing The
1 - RING CAP
2 - PUNCH ACCESS HOLE
3 - RETAINER RING
Fig. 35 Rack Piston End Plug
1 - EXTENSION
2 - END PLUG
3 - RACK PISTON
4 - RATCHET
Fig. 36 Rack Piston with Arbor
1 - RACK PISTON
2 - SPECIAL TOOL C-4175
19 - 30 GEARBR/BE
STEERING GEAR HOUSING PLUG (Continued)

(11) Remove teflon ring and O-ring from the rack
piston (Fig. 38).
(12) Remove the adjuster lock nut and adjuster
nut from the stub shaft.
(13) Pull the stub shaft with the spool valve and
thrust support assembly out of the housing.
(14) Remove the worm shaft from the housing
(Fig. 39).
INSTALLATION
NOTE: Clean and dry all components and lubricate
with power steering fluid.
(1) Check for scores, nicks or burrs on the rack
piston finished surface. Slight wear is normal on the
worm gear surfaces.
(2) Install O-ring and teflon ring on the rack pis-
ton.
(3) Install worm shaft in the rack piston and align
worm shaft spiral groove with rack piston ball guide
hole (Fig. 40).
Fig. 37 Rack Piston
1 - CLAMP
2 - BALLS
3 - RACK PISTON
4 - BALL GUIDE
Fig. 38 Rack Piston Teflon Ring and O-Ring
1 - TEFLON SEAL
2 - BACK-UP O-RING MUST BE INSTALLED UNDER PISTON
RING
3 - RACK PISTON NUT
Fig. 39 Worm Shaft
1 - GEAR HOUSING
2 - BEARING RACE
3 - WORM SHAFT
4 - BEARING
Fig. 40 Installing Balls in Rack Piston
1 - INSTALL BALLS IN THIS HOLE WHILE SLOWLY ROTATING
WORM COUNTER CLOCKWISE
2 - WORM FLANGE
BR/BEGEAR 19 - 31
WORM SHAFT (Continued)

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION.........................33
OPERATION...........................33
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 33
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION....33
STANDARD PROCEDURE - FLUSHING
POWER STEERING SYSTEM............34
REMOVAL
REMOVAL - GASOLINE ENGINE..........35
REMOVAL - DIESEL ENGINE............36
INSTALLATION
INSTALLATION - GASOLINE ENGINE......37INSTALLATION - DIESEL ENGINE.........37
SPECIAL TOOLS
POWER STEERING PUMP..............38
PULLEY
REMOVAL.............................38
INSTALLATION.........................39
HOSES - PRESSURE
DESCRIPTION.........................39
OPERATION...........................39
HOSES - RETURN
DESCRIPTION.........................39
OPERATION...........................39
PUMP
DESCRIPTION
The P-Series pump is used on these vehicles (Fig.
1). The pump shaft has a pressed-on pulley that is
belt driven by the crankshaft pulley on gasoline
engines. The pump is driven off the back of the vac-
uum pump on the diesel engine.
Trailer tow option vehicles are equipped with a
power steering pump oil cooler. The oil cooler is
mounted to the front crossmember.
NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.
OPERATION
Hydraulic pressure is provided by the pump for the
power steering gear. The power steering pump is a
constant flow rate and displacement, vane-type
pump. The pump is connected to the steering gear
via the pressure hose and the return hose. On vehi-
cles equipped with a hydraulic booster, the pump
supplies the hydraulic pressure for the booster.
DIAGNOSIS AND TESTING - PUMP LEAKAGE
(1) Possible pump leakage areas. (Fig. 2).
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Fig. 1 P-SeriesÐPump
1 - RESERVOIR CAP AND DIPSTICK
2 - RESERVOIR
BR/BEPUMP 19 - 33

Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal temperature.
(1) Turn steering wheel all the way to the left
(2) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(3) Raise the front wheels off the ground.
(4) Slowly turn the steering wheel lock-to-lock 20
times with the engine off while checking the fluid
level.
NOTE: Vehicles with long return lines or oil coolers
turn wheel 40 times.
(5) Start the engine. With the engine idling main-
tain the fluid level.
(6) Lower the front wheels and let the engine idle
for two minutes.
(7) Turn the steering wheel in both direction and
verify power assist and quit operation of the pump.If the fluid is extremely foamy or milky looking,
allow the vehicle to stand a few minutes and repeat
the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - FLUSHING POWER
STEERING SYSTEM
Flushing is required when the power steering/hy-
draulic booster system fluid has become contami-
nated. Contaminated fluid in the steering/booster
system can cause seal deterioration and affect steer-
ing gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.
(2) Remove the return line from the pump.
NOTE: If vehicle is equipped with a hydraulic
booster remove both return lines from the pump.
Fig. 2 POWER STEERING PUMP
1 - CHECK OIL LEVEL; IF LEAKAGE PERSISTS WITH THE
CORRECT LEVEL AND CAP TIGHT, REPLACE THE CAP
2 - SHAFT SEAL3 - RESERVOIR O-RING
4 - O-RING SEAL
19 - 34 PUMPBR/BE
PUMP (Continued)

(3) Plug the return line port/ports at the pump.
(4) Position the return line/lines into a large con-
tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir
start the engine.
(6) With the engine running at idle turn the wheel
back and forth.
NOTE: Do not contact or hold the wheel against the
steering stops.
(7) Run a quart of fluid through the system then
stop the engine and install the return line/lines.
(8) Fill the system with fluid and perform Steering
Pump Initial Operation, (Refer to 19 - STEERING/
PUMP - STANDARD PROCEDURE).
(9) Start the engine and run it for fifteen minutes
then stop the engine.
(10) Remove the return line/lines from the pump
and plug the pump port/ports.
(11) Pour fresh fluid into the reservoir and check
the draining fluid for contamination. If the fluid is
still contaminated, disassemble and clean the steer-
ing gear and flush the system again.
(12) Install the return line/lines and perform
Steering Pump Initial Operation, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
REMOVAL
REMOVAL - GASOLINE ENGINE
(1) Remove the serpentine drive belt, (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL) OR (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - REMOVAL).
(2) Remove the hoses from the power steering
pump and cap the fittings.
(3) Remove battery ground cable and unthread
stud from cylinder head, do not remove from bracket.
(4) Loosen upper bracket bolt and remove the
lower bracket to engine block bolts.
(5) Pivot the pump assembly past the coolant tube.
(6) Remove the upper stud and remove upper bolt
from cylinder head.
(7) Remove steering pump and mounting bracket
from engine as an assembly.
(8) Remove the pump pulley with Puller C-4333, to
access pump attaching bolts, (Refer to 19 - STEER-
ING/PUMP/PULLEY - REMOVAL).
(9) Remove the front pump bracket (Fig. 3). On
8.0L engine remove rear pump bracket (Fig. 4).
Fig. 3 Pump Mounting 8.0L
1 - FRONT BRACKET
2 - REAR BRACKET
3 - STEERING PUMP
4 - PULLEY
Fig. 4 Pump Mounting 8.0L
1 - FRONT BRACKET
2 - REAR BRACKET
3 - STEERING PUMP
4 - PULLEY
BR/BEPUMP 19 - 35
PUMP (Continued)

INSTALLATION
INSTALLATION - GASOLINE ENGINE
(1) Install the front pump bracket and tighten
bolts to 47 N´m (35 ft. lbs.). On 8.0L engine install
rear pump bracket and tighten nut to 47 N´m (35 ft.
lbs.), tighten bolts to 24 N´m (18 ft. lbs.).
(2) Install the pump pulley with Installer
C-4063±B, (Refer to 19 - STEERING/PUMP/PULLEY
- INSTALLATION).
(3) Install steering pump assembly on the engine
block. Install the upper stud and bolt in bracket.
(4) Pivot the pump down past the coolant tube and
install the lower bolts in bracket.
(5) Tighten the bolts and nut to 41 N´m (30 ft.
lbs.).
(6) Connect the hoses to the pump.
(7) Install the serpentine drive belt, (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION), (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - INSTALLATION).
(8) Fill the reservoir with power steering fluid,
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE).
INSTALLATION - DIESEL ENGINE
(1) Install the two pump body spacers.
(2) Rotate the drive gear until the steering pump
and vacuum pump drive dogs align. Install the steer-
ing pump onto the vacuum pump bracket. Use care
to avoid damaging the oil seal in the vacuum pump
during installation.The steering pump housing
and spacers must mate completely with the
vacuum pump bracket.
(3) Install the vacuum pump bracket to steering
pump nuts and tighten to 24 N´m (18 ft. lbs.).
(4) Position new gasket on vacuum pump assem-
bly. Use sealer if necessary to retain the gasket.
(5) Align and install the pump assembly on the
engine. Ensure the steering pump stud is inserted
into the block bracket. Tighten the pump- to-engine
block attaching bolts to 77 N´m (57 ft. lbs.).
(6) Install the steering pump to attaching bracket
nut and tighten to 24 N´m (18 ft. lbs.).
(7) Remove plug and install the oil pressure send-
ing unit and electrical connector.
(8) Install the oil feed line to the vacuum pump.
Tighten the oil line connection to 7 N´m (60 in. lbs./ 5
ft. lbs.).
Fig. 8 Bracket Mounting Nuts
1 - VACUUM PUMP
2 - ATTACHING NUTS
3 - STEERING PUMP
4 - PUMP SPACERS
5 - OIL FEED FITTING
Fig. 9 Steering Pump & Vacuum Pump
1 - PUMP SHAFT
2 - VACUUM FITTING
3 - VACUUM PUMP DRIVE
4 - OIL SEAL
5 - MOUNTING BRACKET
6 - DRIVE DOG
7 - PUMP SPACERS
BR/BEPUMP 19 - 37
PUMP (Continued)