lock DODGE RAM SRT-10 2006 Service Repair Manual

RETURN HOSE - COOLER TO PUMP
NOTE: Review all Warnings and Cautions. (Refer
to 19 - STEERING - WARNING).
CAUTION: Cap all open ends of power steering
hoses, power steering pump fittings and steering
gear ports when disconnected. This will prevent
the entry of foreign material into the components
during servicing.
1. Siphon power steering fluid from fluid reservoir.
2. Remove clamp, then return hose at reservoir.
3. Raise vehicle. (Refer to LUBRICATION & MAINTE-
NANCE/HOISTING - STANDARD PROCEDURE)
4. Remove front air deflector.
5. Disconnect the quick connect fitiing (6) at the
return hose from the metal line at the cooler using
special tool 8875.
INSTALLATION
PRESSURE HOSE - PUMP TO FAN
NOTE: Before installing power steering hose, replace used O-rings as necessary. Clean hose ends and open
ports with a lint-free cloth. Lubricate O-rings with clean power steeringfluid.
1. If pressure hose is separate from quick-connect fittings:
a. Thread quick-connect fitting (8) into cooling fan port. Tighten fittingto28Nꞏm(21ft.lbs.)torque.
b. Slide fan end of pressure hose tube into quick-connect fitting until it locks into place.
2. If pressure hose has quick-connect fittings installed on ends, thread fan end quick-connect fitting into fan port.
Tighten hose fitting to 28 Nꞏm (21 ft. lbs.) torque.
3. Install power steering pressure hose into routing clip (7) on cooling module (5).

4. If pressure hose is separate from quick-connect fittings:
a. Thread quick-connect fitting into power steering pump pressure fitting (10). Tighten hose fitting to 28 Nꞏm (21
ft. lbs.) torque.
b. Slide pump end of pressure hose tube into quick-connect fitting until itlocks into place.
5. If pressure hose has quick-connect fittings installed on ends, thread pump end quick-connect fitting into power
steering pump pressure fitting. Tighten fitting to 28 Nꞏm (21 ft. lbs.) torque.
6. Fill power steering pump reservoir to correct fluid level. (Refer to 19 -STEERING/PUMP/FLUID - STANDARD
PROCEDURE)
7. Perform Power Steering Pump Initial Operation procedure. (Refer to 19 -STEERING/PUMP - STANDARD PRO-
CEDURE).
8. Check for leaks at all hose connections.
PRESSURE HOSE - FAN TO GEAR
NOTE: Before installing power steering hose,
replace used O-rings as necessary. Clean hose
ends and open ports with a lint-free cloth. Lubri-
cate O-rings with clean power steering fluid.
1. Thread power steering pressure hose tube nut on
end of hose into power steering gear port. Tighten
tube nut to 28 Nꞏm (21 ft. lbs.) torque.
2. If fan end of pressure hose is separate from quick-
connect fitting:
a. Thread quick-connect fitting (6) into cooling fan
port (1). Tighten fitting to 28 Nꞏm (21 ft. lbs.)
torque.
b. Slide fan end of pressure hose tube into quick-
connect fitting until it locks into place.
3. If fan end of pressure hose has quick-connect fit-
ting installed, thread fan end quick-connect fitting
into fan port. Tighten fitting to 28 Nꞏm (21 ft. lbs.)
torque.
4. Fill power steering pump reservoir to correct fluid level. (Refer to 19 -STEERING/PUMP/FLUID - STANDARD
PROCEDURE)
5. Perform Power Steering Pump Initial Operation procedure. (Refer to 19 -STEERING/PUMP - STANDARD PRO-
CEDURE).
6. Check for leaks at all hose connections.

RESERVOIR
REMOVAL
1. Remove power steering pump from vehicle. (Refer
to 19 - STEERING/PUMP - REMOVAL)
2. Clean exterior of pump.
3. Clamp pump body in a soft jaw vice.
NOTE: Use new retaining clips for installation.
4. Pry up tab and slide each retaining clip (2) off
pump (1). Discard clips (2).
5. Remove fluid reservoir (1) from pump housing.
Remove and discard O-ring seal.
INSTALLATION
1. Lubricate new O-ring Seal with clean ATF+4 fluid or
equivalent.
2. Install O-ring seal in housing.
3. Install reservoir (1) onto housing.
4. Slide and tap in NEW reservoir retainer clips (2)
making sure each tab locks into place on housing.
5. Install power steering pump on vehicle. (Refer to 19 - STEERING/PUMP - INSTALLATION)
6. Fill power steering pump reservoir to correct fluid level. (Refer to 19 -STEERING/PUMP/FLUID - STANDARD
PROCEDURE)

14. Remove structural dust cover (1) clutch housing
bolts (2) and dust shield bolts (3) on 5.7L engine.
CAUTION: On 5.7L engine do not remove struc-
tural dust cover from engine block. If cover is
removed clutch housing and structural dust cover
must be aligned with the engine.
15. Remove exhaust bracket (1) bolts and remove
bracket on diesel engine.

16. Support engine with adjustable jack stand and
wood block.
17. Support and secure transmission (1) to a trans-
mission jack (2) with safety chains.
18. Remove transmission mount bolts (1).
19. Remove rear crossmember bolts (2) and remove
crossmember with transmission mount.
20. Remove exhaust Y-pipe on 5.7L engine.
21. Remove bolts attaching transmission to the
engine.
22. Move transmission rearward until input shaft is
clear of clutch disc and pressure plate. Then
lower jack and remove transmission from under
vehicle.

22. Remove reverse gear synchronizer hub (1)
detents (2).
23. Remove mainshaft bearing (1) with Bridge 938 (2)
and bearing Puller 9647 (3).
24. Position puller (1) behind reverse synchronizer
hub and outer blocker ring (2).

7. Install second gear blocker ring (1) on stop ring (2).
8. Install 1-2 synchronizer hub (1) on mainshaft and
synchronizer rings (2).
9. Install 1-2 synchronizer hub (1) and hub snap ring
(2).

10. Install 1-2 synchronizer sleeve (3) on the hub (2)
and push sleeve to the bottom of the hub.
NOTE: 1-2 synchronizer sleeve (3) and hub (2)
have one small tooth. They must be aligned to
install synchronizer sleeve (3) on hub (2).
11. Install 1-2 synchronizer detents and springs (1)
into synchronizer hub (2) slots. Then push detents
behind synchronizer sleeve (3).
12. Install first gear blocker ring (1) on synchronizer
hub (2).
13. Install first gear outer friction ring (1) on synchro-
nizer hub (2).

21. Install reverse gear inner friction ring (1) on
reverse gear (2).
22. Install reverse gear outer friction ring (1) on inner
blocker ring (2).
23. Install reverse gear blocker ring (1) on friction ring
(2).

35. Install third gear outer friction ring (1) on stop ring
(2).
36. Install third gear blocker ring (1) on stop ring (2).
37. Install 3-4 synchronizer hub (1) on third gear syn-
chronizer rings (2).