Ok here is the bulletin I found on your subject. You may want to check the part number and check the procedure and see if it is possible a mistake was made with one of the seals (we all do it) and if not and you decide to take it apart and check look for o rings that may have got cut when installing them. I usually use something like vaseline when installing O-rings and if the surfaces don't look as good where the o-rings go you may want to try and small amount of silicone, careful not to seal up the weep hole that is in the bottom of the housing to let you know there is a leak.
Also please do check your vacuum lines to see if they are all oily. If they are they could be draining back on your repair and fooling us both.
Thanks and I hope this helps, Please let me know how you progress.
DATE: March 16, 2004
This bulletin is supplied as technical information only and is not an authorization for repair. .
Vacuum Pump Service
2000 - 2002 (BR/BE) Ram Truck
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.
Qty. Part No. Description
1 05140342AA Vacuum Pump Seal Kit
NOTE: This Bulletin Applies to Vehicles Equipped With Cummins Diesel
Engines, Sales Code ETC or ETH.
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).
Fig. 1 VACUUM PUMP REMOVAL
8. Remove two cap screws holding vacuum pump housing and vacuum pump
bearing housing. Remove the bearing housing (Fig. 2).
Fig. 2 BEARING HOUSING
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).
Fig. 3 SEAL RETAINER REMOVAL
10. Remove O-ring from the shaft seal sleeve and discard (Figure 5).
Fig. 4 SHAFT SLEEVE O-RING
1 - O-Ring
11. Using a 1-3/8" drift or equivalent OD socket, press the seal out of the sleeve (Figure 6).
Fig. 5 SEAL REMOVAL
1 - Socket
12. Thoroughly clean all parts prior to assembly.
13. Lubricate the OD of the new shaft seal with engine oil and press it 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.
Fig. 6 SEAL INSTALLATION
1 - Seal
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.
Fig. 7 SHAFT SLEEVE O-RING
1 - O-Ring
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).
Fig. 8 BEARING HOUSING
1 - Cross Coupling
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.
Fig. 9 SHAFT SLEEVE INSTALLATION
1 - Shaft Sleeve
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.
Fig. 10 VACUUM PUMP
1 - Large O-Ring
2 - Drive Tangs
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 cap screws and torque to 30 Nm (22 ft-lb) (Figure 16).
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 (Figure 17). 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.
Fig. 11 VACUUM PUMP INSTALLATION
1 - Drive Dogs
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 ft-lb), and torque the M10 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.