TECH NOTES: Installation Instructions
TECH NOTES: Installation Instructions NOTE: READ INSTRUCTIONS THOROUGHLY BEFORE INSTALLATION WORK BEGINS
Dorman Part: 904-809 Vacuum Pump Installation Instructions 1991-89 Dodge D/W Series Pickup I6-5.9L Diesel ATTENTION: Refer to the appropriate shop manual for your vehicle to obtain specific service procedures for this part. If you do not have a service manual or lack the skill to install this part, it is recommended that you seek the services of a qualified technician. Pay special attention to all cautions and warnings included in the shop manual. Read and follow all instructions carefully.
DISASSEMBLY
Remove the vacuum and power steering pump assembly. 1. Clean gasket from engine gear cover.
Disclaimer: Even though every attempt is made to ensure this information is complete and accurate, it is impossible to account for all possible circumstances or situations. Please consult with a qualified auto technician before attempting to perform any work you are not qualified to do. Automobiles can be hazardous to work on; be sure to take all necessary safety precautions. Failure to do so may result in property damage or personal injury. Certain motor vehicle standards and performance requirements may apply to our motor vehicle (such as Federal Motor Vehicle Safety Standards by the National Highway Traffic Safety Administration). Be sure that your work is performed in accordance with such standards and that you do not disable any motor vehicle safety feature.
TECH NOTES: Installation Instructions NOTE: READ INSTRUCTIONS THOROUGHLY BEFORE INSTALLATION WORK BEGINS
3. Fabricate a pin, from an 8 mm hardened drill rod or a grade 8 capscrew.
4. Insert the pin into the pump shaft, then screw a M14 X 2 mm threaded capscrew in the shaft against the pin. 5. Tighten the capscrew against the pin, then remove the gear, eccentric and bearing assembly from the power steering pump shaft. 6. If gear or eccentric is not damaged, do not separate them. If damage is present, press the eccentric out of the gear. 7. Visually inspect the bearing while rotating by hand, if the bearing looks good and feels smooth to the turn, do not separate it. 8. If replacement of the bearing or eccentric is necessary, press the eccentric out from the bearing using an appropriate size socket or tool that will press only on the inner race of the bearing. Press bearing or eccentric on until it bottoms. 9. Remove the four nuts and separate the power steering pump from the vacuum pump housing. 10. Remove the pushrods. Ensure pushrods slide smoothly in the bushings and no side to side movement is present. 11. Remove the diaphragm assemblies from the housing. If the diaphragms are to be replaced, they must replaced as a unit. 12. Remove and discard O-rings from center and pushrod bores. 13. Clean parts in suitable solvent and dry with compressed air.
Disclaimer: Even though every attempt is made to ensure this information is complete and accurate, it is impossible to account for all possible circumstances or situations. Please consult with a qualified auto technician before attempting to perform any work you are not qualified to do. Automobiles can be hazardous to work on; be sure to take all necessary safety precautions. Failure to do so may result in property damage or personal injury. Certain motor vehicle standards and performance requirements may apply to our motor vehicle (such as Federal Motor Vehicle Safety Standards by the National Highway Traffic Safety Administration). Be sure that your work is performed in accordance with such standards and that you do not disable any motor vehicle safety feature.
TECH NOTES: Installation Instructions NOTE: READ INSTRUCTIONS THOROUGHLY BEFORE INSTALLATION WORK BEGINS
ASSEMBLY 1. Install two spacers on the studs of power steering pump. 2. Install the vacuum pump housing onto the power steering pump, using a new O-ring lubricated with engine oil. Torque retaining nuts to 18 ft. lbs.
3. Install the gear, eccentric and bearing assembly by pulling it onto the power steering shaft using a 3/8 X 18 inch capscrew and a flat washer, until it bottoms out. This is a press fit and will require a minimum of SAE grade 8 capscrew for thread strength. 4. Remove capscrew and washer from the shaft. 5. Lubricate pushrods with engine oil, then install them in the housing. 6. Install new O-rings, lubricating with engine oil. 7. Install diaphragm assemblies, torquing the retaining bolts to 7 ft. lbs. 8. Install the power steering/vacuum pump assembly onto the engine with a new gasket. Torque attaching bolts to 57 ft. lbs.
Disclaimer: Even though every attempt is made to ensure this information is complete and accurate, it is impossible to account for all possible circumstances or situations. Please consult with a qualified auto technician before attempting to perform any work you are not qualified to do. Automobiles can be hazardous to work on; be sure to take all necessary safety precautions. Failure to do so may result in property damage or personal injury. Certain motor vehicle standards and performance requirements may apply to our motor vehicle (such as Federal Motor Vehicle Safety Standards by the National Highway Traffic Safety Administration). Be sure that your work is performed in accordance with such standards and that you do not disable any motor vehicle safety feature.
Dorman Part: 904-809 Vacuum Pump Installation Instructions 1991-89 Dodge D/W Series Pickup I6-5.9L Diesel ATTENTION: Refer to the appropriate shop manual for your vehicle to obtain specific service procedures for this part. If you do not have a service manual or lack the skill to install this part, it is recommended that you seek the services of a qualified technician. Pay special attention to all cautions and warnings included in the shop manual. Read and follow all instructions carefully.
DISASSEMBLY
Remove the vacuum and power steering pump assembly. 1. Clean gasket from engine gear cover.
Disclaimer: Even though every attempt is made to ensure this information is complete and accurate, it is impossible to account for all possible circumstances or situations. Please consult with a qualified auto technician before attempting to perform any work you are not qualified to do. Automobiles can be hazardous to work on; be sure to take all necessary safety precautions. Failure to do so may result in property damage or personal injury. Certain motor vehicle standards and performance requirements may apply to our motor vehicle (such as Federal Motor Vehicle Safety Standards by the National Highway Traffic Safety Administration). Be sure that your work is performed in accordance with such standards and that you do not disable any motor vehicle safety feature.
TECH NOTES: Installation Instructions NOTE: READ INSTRUCTIONS THOROUGHLY BEFORE INSTALLATION WORK BEGINS
3. Fabricate a pin, from an 8 mm hardened drill rod or a grade 8 capscrew.
4. Insert the pin into the pump shaft, then screw a M14 X 2 mm threaded capscrew in the shaft against the pin. 5. Tighten the capscrew against the pin, then remove the gear, eccentric and bearing assembly from the power steering pump shaft. 6. If gear or eccentric is not damaged, do not separate them. If damage is present, press the eccentric out of the gear. 7. Visually inspect the bearing while rotating by hand, if the bearing looks good and feels smooth to the turn, do not separate it. 8. If replacement of the bearing or eccentric is necessary, press the eccentric out from the bearing using an appropriate size socket or tool that will press only on the inner race of the bearing. Press bearing or eccentric on until it bottoms. 9. Remove the four nuts and separate the power steering pump from the vacuum pump housing. 10. Remove the pushrods. Ensure pushrods slide smoothly in the bushings and no side to side movement is present. 11. Remove the diaphragm assemblies from the housing. If the diaphragms are to be replaced, they must replaced as a unit. 12. Remove and discard O-rings from center and pushrod bores. 13. Clean parts in suitable solvent and dry with compressed air.
Disclaimer: Even though every attempt is made to ensure this information is complete and accurate, it is impossible to account for all possible circumstances or situations. Please consult with a qualified auto technician before attempting to perform any work you are not qualified to do. Automobiles can be hazardous to work on; be sure to take all necessary safety precautions. Failure to do so may result in property damage or personal injury. Certain motor vehicle standards and performance requirements may apply to our motor vehicle (such as Federal Motor Vehicle Safety Standards by the National Highway Traffic Safety Administration). Be sure that your work is performed in accordance with such standards and that you do not disable any motor vehicle safety feature.
TECH NOTES: Installation Instructions NOTE: READ INSTRUCTIONS THOROUGHLY BEFORE INSTALLATION WORK BEGINS
ASSEMBLY 1. Install two spacers on the studs of power steering pump. 2. Install the vacuum pump housing onto the power steering pump, using a new O-ring lubricated with engine oil. Torque retaining nuts to 18 ft. lbs.
3. Install the gear, eccentric and bearing assembly by pulling it onto the power steering shaft using a 3/8 X 18 inch capscrew and a flat washer, until it bottoms out. This is a press fit and will require a minimum of SAE grade 8 capscrew for thread strength. 4. Remove capscrew and washer from the shaft. 5. Lubricate pushrods with engine oil, then install them in the housing. 6. Install new O-rings, lubricating with engine oil. 7. Install diaphragm assemblies, torquing the retaining bolts to 7 ft. lbs. 8. Install the power steering/vacuum pump assembly onto the engine with a new gasket. Torque attaching bolts to 57 ft. lbs.
Disclaimer: Even though every attempt is made to ensure this information is complete and accurate, it is impossible to account for all possible circumstances or situations. Please consult with a qualified auto technician before attempting to perform any work you are not qualified to do. Automobiles can be hazardous to work on; be sure to take all necessary safety precautions. Failure to do so may result in property damage or personal injury. Certain motor vehicle standards and performance requirements may apply to our motor vehicle (such as Federal Motor Vehicle Safety Standards by the National Highway Traffic Safety Administration). Be sure that your work is performed in accordance with such standards and that you do not disable any motor vehicle safety feature.
