Tools You'll Need:
* Pulley puller: This is absolutely essential. You'll need a puller specifically designed for this type of application. A three-jaw puller is commonly used. Make sure it's the correct size to fit your water pump pulley. Improper fit could damage the pulley or water pump.
* Socket wrench and appropriate socket: To remove the pulley nut. The size will likely be a large, deep well socket. This nut is typically very tight.
* Breaker bar or ratchet with extension: You'll need significant leverage to break the nut loose.
* Impact wrench (recommended): An impact wrench can significantly simplify loosening the stubborn nut. If you don't have one, be prepared for considerable effort with a breaker bar.
* Penetrating oil (PB Blaster or similar): Apply generously to the pulley nut several hours (or even overnight) before attempting to remove it. This will help break down corrosion and make it easier to loosen.
* Wrench or socket to hold the crankshaft: You will need to hold the crankshaft from rotating while you loosen the pulley nut. A crankshaft holding tool is ideal, but a strong wrench fitted to a suitable bolt on the crankshaft might work (proceed with extreme caution). Improperly holding the crankshaft could result in damage to the engine.
* Gloves: Protect your hands.
* Safety Glasses: Protect your eyes from flying debris.
Procedure:
1. Preparation: Disconnect the negative battery terminal. This prevents accidental shorts. Allow the engine to cool completely before working on it.
2. Penetrating Oil: Liberally apply penetrating oil to the pulley nut. Let it soak for several hours, or preferably overnight.
3. Crankshaft Hold: Securely hold the crankshaft to prevent it from rotating. This is extremely important.
4. Remove Pulley Nut: Use your socket and wrench (or impact wrench) to loosen and remove the pulley nut. Turn counter-clockwise. Expect significant resistance.
5. Install Pulley Puller: Carefully position the pulley puller on the pulley. Ensure the jaws are evenly gripping the pulley and that the puller is properly centered.
6. Remove Pulley: Slowly tighten the puller's center bolt. This will draw the pulley off the water pump shaft. If the pulley resists, carefully re-check the puller's position and ensure it's correctly seated. Apply more penetrating oil if needed. Avoid excessive force that might damage the water pump shaft.
7. Clean Up: Once the pulley is removed, clean the water pump shaft and the pulley.
Important Considerations:
* If you're not comfortable performing this repair yourself, take it to a qualified mechanic. Incorrectly attempting this repair can lead to damage to your water pump, crankshaft, or other engine components.
* Always use the correct tools. Using the wrong tools can easily strip bolts or damage parts.
* If the pulley nut is extremely difficult to remove, consider using an air impact wrench.
* Be careful not to damage the water pump shaft.
This process describes the general procedure. Specific details may vary slightly depending on the exact configuration of your engine. Consult a repair manual specific to your 2001 Dodge Ram 3500 5.9L for detailed diagrams and instructions. A repair manual will also show you the correct way to hold the crankshaft.
