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TSB 09-009-04

Vacuum Pump Service

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Date: March 16, 2004 

Models: 2000-2002 (BR/BE) Ram Truck

NOTE: This Bulletin Applies to Vehicles Equipped With Cummins Diesel Engines, Sales Code ETC or ETH.

Discussion:
A new vacuum pump seal repair kit has been released, p/n 05140342AA. This kit can be
used to repair oil leaks between the vacuum pump and the power steering pump.
The vacuum pump was previously serviced as an assembly only.

Parts Required:

Qty.	Part No.	Description
1	05140342AA	Vacuum Pump Seal Kit

Repair Procedure: 

1.	Disconnect both batteries.
2.	Drain the power steering pump of fluid.
3.	Disconnect the high-pressure supply hose and the two return hoses from the power steering pump.
4.	Disconnect the vacuum hose from the vacuum pump.
5.	Disconnect the flexible oil supply hose from the vacuum pump.
6.	Remove the vacuum/steering pump assembly from the engine by removing two cap screws from the vacuum pump main flange, and the cap screws holding the steering pump bracket to the cylinder block. Note the position of the block support bracket for reassembly.
7.	Separate vacuum pump from steering pump by removing four (4) nuts M10. Carefully remove the p/s pump from the vacuum pump and set aside (Fig. 1).
8.	Remove two rap screws holding vacuum pump housing and vacuum pump bearing housing. Remove the bearing housing (Fig. 2).
9.	Place vacuum pump bearing housing seal surface facing up. Place 10 mm thick metal plate or similar flat piece to level the housing with the bench (Figure 3). Drive the seal retainer out of the housing using a 1 " OD drift or equivalent deep wall socket and a mallet (Fig. 3).
10.	Remove O-ring from the shaft seal sleeve and discard (Figure 4).
11.	Using a 1-3/8' drift or equivalent OD socket, press the seal out of the sleeve (Figure 5).
12.	Thoroughly clean all parts prior to assembly.
13.	Lubricate the OD of the new shaft seal with engine oil and press fit into the sleeve with the seal face down, (Fig. 6) using a 1-3/8' drift or equivalent size socket, making sure seal is fully seated in the housing.
14.	Install the smaller O-ring from the service kit into the groove on the sleeve (Fig 7).  Lightly lubricate the O-ring with engine oil.
15.	Place vacuum pump bearing housing, sealing face down, on a clean bench (Figure 10). Insert cross coupling plate to the bottom of the bore (Fig. 8).
16.	Install the sleeve, O-ring end first, into the bore by hand. Using a press or rubber mallet, fully press the sleeve into the bore until seated (Fig. 9). Verify the cross coupling plate rotates freely. Verify the O-ring has not been pinched or is out of position.
17.	. Install the larger O-ring included In the service kit in the clean groove of the vacuum pump housing (Fig. 10). Lightly lubricate O-ring with engine oil.
18.	Carefully install the bearing housing to the vacuum pump housing, making sure dowel pin seats into the dowel hole, and the shaft drive tangs align with the cross coupling slot (rotate the pump shaft if necessary (Fig. 10) Secure with two M10 capscrews and torque to 30 Nm (22 ft-lb)
CAUTION: Failure to align drive tangs with the cross coupling slot prior to tightening cap screws will result in pump damage.
19.	Inspect the Power Steering pump drive lug and clean any old seal residue from its surface using solvent and a rag.
20.	Carefully install the power steering pump to the vacuum pump, aligning the drive dogs on the p/s pump shaft with the slots in the cross plate (Fig. 11), making sure the dust lip of the shaft seal is not bent or damaged. Secure with the three nuts to the steering pump stud bolts and torque to 24 Nm (18 ft-lb). Install the pump support bracket to the lower inboard stud; secure finger tight with the remaining nut.
21.	Clean the sealing surface on the accessory drive flange. Install vacuum/steering pump assembly to the engine using a new gasket. Secure with two 12mm cap screws, and torque to 77 Nm (57 ft-lb).
22.	Fasten the power steering pump support bracket to the cylinder block with the M8 cap screw, torque to 24 Nm (18 it-lb), and torque the MIO nut on the steering pump to 24 Nm (18 ft-lb).
23.	Connect the oil feed line to the vacuum pump connector and tighten line fitting. Connect vacuum hose to the vacuum pump and secure with the clamp.
24.	Connect steering pump pressure and return lines to the power steering pump. Tighten the pressure line fitting to 30 Nm (22 ft-lb).
25.	Fill power steering pump reservoir and purge air from steering pump lines.
26.	Reconnect the batteries.

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:

Failure Code:

This page was edited on: May 3, 2004