Dodge ram truck 3500 1996 Service Manual page 1324

14 - 90 FUEL S Y S T E M ^ —
SERVICE PROCEDURES (Continued)
BR
Fig. 54 Oii Filter Tube
removing pump nut or washer, place a magnet to the
end of the injection pump shaft (Fig. 55). This will
prevent the nut or washer from falling into the tim­
ing gear cover which will require engine disassembly
for recovery.
(16) Position a magnet to the end of the injection
pump shaft. Install the special bearing and thrust
washer kit #6862 (Fig. 56) over the injection pump
shaft in this order: 1 thrust washer-1 bearing-1
thrust washer. The thrust washer/bearing kit is used
to prevent the pump gear from rotating on the pump
shaft when tightening the pump nut (step 22). Rein­
stall pump shaft nut allowing some clearance
between the thrust washers. Do not tighten nut at
this time.
PUMP SHAFT
J9514-65
Fig. 55 Positioning Magnet to Pump Shaft
BEARING
THRUST
WASHERS
J9514-85
Fig. 56 Bearing/Thrust Washer Tools
(17) Slowly rotate the engine clockwise until
reaching the required lift setting on the dial indica­
tor. Refer to Fuel Injection Pump Plunger Lift chart
(Fig. 53). The injection pump should rotate with the
engine since the injection pump gear is still locked to
the injection pump shaft.
(18) With the injection pump at the correct
plunger lift setting, use special gear puller tool
#L-4407A to pull the injection pump gear off the
taper of the injection pump input shaft. Leave the
gear puller installed (Fig. 57). After the gear has
been pulled, ensure the lift setting has not changed.
Fig. 57 Gear Puller Tool Installed
(19) Rotate the engine 20 to 30 degrees counter­
clockwise, then rotate the engine back clockwise to
TDC (Fig. 58). This removes backlash from the
geartrain.
The fuel pump gear and pump shaft tapers
must be absolutely clean, dry and free of any
oil or dirt. Oil or dirt will prevent seating of the
taper and will result in possible slippage of the
gear.
(20) Loosen, but do not remove the gear puller tool
bolts. Using the gear puller, rotate pump gear coun-