Dodge Ram Truck 1500-2500-3500. Manual — part 1511

The following procedures are used to test the operation of the power steering and hydraulic fan systems on this
vehicle. These tests will provide the gallons per minute (GPM) or flow rate of the power steering pump along with
the maximum relief pressure at given points in the system. Perform the first test anytime a power steering system
problem is present and the second as necessary once the first test is completed. These tests will determine if the
power steering pump, hydraulic fan, or power steering gear is not functioning properly. They will also determine if
the flow coming out of the hydraulic fan motor is sufficient for the power steering gear. The following pressure and
flow tests are performed using the Power Steering Analyzer kit 6815 (with appropriate hoses) and Adapter kit 9091.
(Refer to 19 - STEERING - SPECIAL TOOLS)

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FLOW AND PRESSURE TEST - AT POWER STEERING PUMP

1. Check power steering belt to ensure it is in good

condition and adjusted properly.

2. Assemble Power Steering Analyzer as follows :

a. Gauge end (inlet) of Flow Meter And Gauge

6800 – Hose 6905, Hose 6713, Adapter Tube
9091-1

b. Valve end (outlet) of Flow Meter And Gauge

6800 – Hose 6959, Adapter Fitting 9091-3

3. Unthread pressure hose quick-connect fitting from

power steering pump.

4. Connect Adapter Tube 9091-1 to pressure fitting on

power steering pump.

5. Connect power steering pressure hose to Adapter

Fitting 9091-3.

6. Open Analyzer test valve completely.

7. Start engine and allow to idle long enough to circulate power steering fluid through Analyzer flow meter and

hoses.

8. Shut off engine and check fluid level; add fluid as necessary. Repeat Step 7 and Step 8 until air is bled from

system.

9. Start engine and allow to idle.

10. Check Analyzer gauge pressure. Initial pressure reading should be 483-690 kPa (70-100 psi). If pressure is

higher, inspect hoses for restrictions and repair as necessary.

11. Increase engine speed to 1100 rpm and read Analyzer Flow Meter. The reading should be 2.6 GPM minimum.

If flow reading is below specification, replace power steering pump.

FLOW AND PRESSURE TEST - AT POWER STEERING GEAR

NOTE: This test should only be done if necessary
after completing the Pump Flow And Pressure Test

1. Remove Analyzer from pump and pressure hose to

fan. Reattach pressure hose to pump.

2. Assemble Power Steering Analyzer as follows :

a. Gauge end (inlet) of Flow Meter And Gauge

6800 – Hose 6959, Adapter Fitting 9091-4

b. Valve end (outlet) of Flow Meter And Gauge

6800 – Hose 6905, Hose 6713, Adapter Tube
9091-2

3. Unthread pressure hose tube nut from power steer-

ing gear.

4. Connect power steering pressure hose to Adapter

Fitting 9091-4.

5. Connect Adapter Tube 9091-2 to power steering

gear.

6. Open Analyzer test valve completely.

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7. Start engine and allow to idle long enough to circulate power steering fluid through Analyzer flow meter and

hoses.

8. Shut off engine and check fluid level; add fluid as necessary. Repeat Step 7 and Step 8 until air is bled from

system.

9. Start engine and allow to idle.

10. Check Analyzer gauge pressure. Initial pressure reading should be 345-552 kPa (50-80 psi). If pressure is

higher, inspect hoses for restrictions and repair as necessary.

11. Increase engine speed to 1500 RPM and read Analyzer Flow Meter. The reading should be 2.4 - 2.8 GPM. If

flow reading is below specification, replace hydraulic fan.

CAUTION: This next step involves testing maximum fan motor steering relief pressure. Do not leave the
valve closed for more than three seconds.

12. Close Analyzer valve fully three times for three seconds each time and record highest pressure indicated on

Analyzer gauge each time. All three readings must be within fan motor steering relief pressure specifications.

13. Completely open test valve and turn steering wheel to the extreme left and right positions against stops. Record

the highest pressure readings at each position. If pressure readings are not within 50 psi from each other, the
gear is leaking internally and must be replaced.

PUMP OUTLET SPECIFICATIONS

ENGINE

RELIEF PRESSURE

FLOW RATE (GPM) @ 1100 RPM

ALL

9653 kPa ± 345 kPa

(1400 psi ± 50 psi)

2.4-2.8 GPM Minimum @ 1379 kPa (200

psi)

GEAR INLET SPECIFICATIONS

ENGINE

RELIEF PRESSURE

FLOW RATE (GPM) @ 1500 RPM

ALL

9653 kPa ± 345 kPa

(1400 psi ± 50 psi)

2.4-2.8 GPM Minimum @ 1379 kPa (200

psi)

STANDARD PROCEDURE

INITIAL OPERATION

WARNING: THE FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOV-
ING COMPONENTS.

NOTE: Remove as much of the old fluid out of the system as possible with a suction tool or by removing
a hose, When a component has failed. Then refill it with fresh fluid until it is clean. This may have to be
done more than once.

CAUTION: MOPAR

ATF+4 is to be used in the power steering system. No other power steering or auto-

matic transmission fluid is to be used in the system. Damage may result to the power steering pump and
system if any other fluid is used, and do not overfill.

Wipe filler cap clean, then check the fluid level. The dipstick should indicate COLD when the fluid is at normal
ambient temperature.

1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two minutes.

2. Start the engine and let run for a few seconds then turn engine off.

3. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine.

4. Raise the front wheels off the ground.

5. Slowly turn the steering wheel right and left, lightly contacting the wheel stops at least 20 times.

6. Check the fluid level add if necessary.

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7. Lower the vehicle, start the engine, and use the DRB III to activate the hydraulic fan on full fan operation.

8. Turn the steering wheel slowly from lock to lock.

9. Stop the engine, check the fluid level and refill as required and repeat the process

CAUTION: Do not run a vehicle with foamy fluid for an extended period. This may cause pump damage.

10. If the fluid is extremely foamy or milky looking, allow the vehicle to stand a few minutes and repeat the pro-

cedure.

11. While the vehicle is in park, use the DRB III to activate the hydraulic fan to full fan operation and briefly rev the

engine up to 3000 rpm to fully engage the hydraulic fan.

12. Check the fluid level add if necessary.

STANDARD PROCEDURE - FLUID COOLER LINE QUICK CONNECT FITTING
DISASSEMBLY/ASSEMBLY

DISASSEMBLY

1. Remove dust cap (2) by pulling it straight back off

of quick connect fitting (1).

2. Place disconnect tool (Special Tool 8875) (4) onto

fluid cooler line with the fingers of the tool facing
the quick connect fitting (1).

3. Slide disconnect tool down the line (3) and engage

the fingers of the tool into the retaining clip. When
properly engaged in the clip, the tool will fit flush
against the quick connect fitting (1).

4. Rotate the disconnect tool 60° to expand the

retaining clip.

5. While holding the disconnect tool (4) against the

quick connect fitting (1), pull back on the oil cooler
line to remove.

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Dodge Ram Truck 1500-2500-3500. Manual — part 1511

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