This is how to re-seal a 96-02 dodge cummins 2-piece vacuum pump. I did it on mine, and found it cured 2 leaks. 1 where the pump mounts to the timing case, the other at the rear, where the power steering pump mounts to. Took about 30 minutes to do, and pretty easy. I attached my own photos, because parts of it can be un-clear at times (although it's easy to figure out).
Remove the vacuum pump from the truck. I found it easier to do with the power steering pump attached. The nuts that join the power steering pump to the vacuum pump are 15mm if you choose to remove the pump. I found it hard to get to the 2 inboard-most nuts with anything. Pete Gould (maker of the kit) shaved a box-end wrench down, then bent it to get it to work. I couldn't justify bending and grinding my only 15mm wrench, and since I was replacing the pump anyway, I decided to take them out as one.
Although mine didn't have it, there is a bracket that goes on the inboard, lower stud for the power steering pump. You'll need to remove the bolt from the block to remove the pump, and the bracket can stay on the pump stud (not sure on the size, since mine didn't have it).
Next is the oil drain line. I'll have to dig through my notes for the size, but it's somewhere around a 3/8" fitting. The best way to remove it is to use a flare nut wrench. They have more gripping surface, so you don't round the nut off. If you can, spray the fitting with penetrating oil a few days in advance. When you remove it, hold the line so it doesn't turn on you.
Once that's off, the rest is fairly easy. Remove the two spring clamps from the lines on the power steering pump, and the remaining line with a wrench (I will have the size up soon). Remove the plastic vaccum line/elbow from the vacuum pump and wiggle it out.
I replaced all the lines from mine, so the pressure lines were not a problem. They may pose a problem if you aren't removing them. If so, you can leave the lines on the power steering pump, and set it out of the way, then remove the vacuum pump by itself. You can also get at the studs and nuts easier, as you can manipulate it around. Then, you are done with the removal. Just make sure to take out and discard the gasket inbetween the vacuum pump and timing case.
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