Water pump R & R, 2004.5 with shortcuts
10-01-2015, 02:35 AM
#91
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Just got this done today. My pump went **** up at 80,000 miles. This write up is full of great info, was very helpful. Mine was a total pain, but only because I ran into problems. The tensioner broke immediately when I tried to release the belt tension. Barely even torquing on it when it broke. So I had to run to Napa for a new tensioner, then wrestle around with putting a new serpentine on, what a pain.
But now that I know what I'm doing, it'll be simple next time. The write up was incredibly helpful. Shouldn't have to mess with it for a long time now though. Did the full flush, new zerex g5, new serpentine belt, new t-stat, new water pump, and new tensioner pulley which is the only unexpected new part. Also 2 new batteries, got almost 10 years out of the originals.
But now that I know what I'm doing, it'll be simple next time. The write up was incredibly helpful. Shouldn't have to mess with it for a long time now though. Did the full flush, new zerex g5, new serpentine belt, new t-stat, new water pump, and new tensioner pulley which is the only unexpected new part. Also 2 new batteries, got almost 10 years out of the originals.
03-06-2016, 09:12 AM
#93
Registered User
i wonder what the problem is with the newer 5.9 water pumps? i am still on the original at 280,000 miles.....they look to be the same, maybe they used cheaper seals and bearings after 2002
03-19-2016, 05:26 PM
#94
Advocate of getting the ban button used on him...
Just turned 158k miles on the 06. Noticed the drip drip yesterday. Praying I can get a few days out of it cuz I work until Wednesday 
05-15-2016, 09:49 PM
#95
Replaced the WP on our '03 this morning with 204,200 on the clock. Since we are in an RV park, I had to kind of do it incognito. I have carried the pump for several years along with a thermostat. What a piece of cake! Loosened the serpentine belt. Used a siphon pump from the Big Boys' Toy Store (Harbor Freight) to pull the coolant out and into two buckets. Removed the old pump, set the new pump in the hole, tightened the belt. Then removed the thermostat housing, refilled the coolant thru that hole, set new thermostat in, tightened down, then finished filling the system thru the radiator cap hole. Started at 7 AM. finished at 9 AM, ready for the road test. Everything seems dry now.
05-16-2016, 08:43 PM
#97
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Replaced the WP on our '03 this morning with 204,200 on the clock. Since we are in an RV park, I had to kind of do it incognito. I have carried the pump for several years along with a thermostat. What a piece of cake! Loosened the serpentine belt. Used a siphon pump from the Big Boys' Toy Store (Harbor Freight) to pull the coolant out and into two buckets. Removed the old pump, set the new pump in the hole, tightened the belt. Then removed the thermostat housing, refilled the coolant thru that hole, set new thermostat in, tightened down, then finished filling the system thru the radiator cap hole. Started at 7 AM. finished at 9 AM, ready for the road test. Everything seems dry now.
09-03-2016, 09:31 PM
#98
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Great write up and used this as my guide when replacing mine. My notes: When draining the system, slightly loosing the pump bolts facilitated draining and also detaching itself from the block, IE I did not have to pry the old pump off the block. My Gates replacement looked exactly like what was on the truck, fairly certain it was not the original, however it looks exactly like what OP took off his truck originally. Short cut #2 is great, I had no issues filling the system either during flush or final fill up.
2003 232,000. fourth owner or something.
2003 232,000. fourth owner or something.
08-13-2017, 02:33 PM
#99
2nd owner here on my 2500 2005. bought at 20k miles and just now 205,000 miles my WP finally went out. noticed my temps on OEM gauge and BD pmt tuner goin up to about 220 and defueling. whenever i would stop, it would be raining from the bottom pulley and i couldnt source where from. Thanks to all these awesome years of forums.. i am about to go buy and change out the WP, tensioner ,thermo and belt.
hope it goes as easy as everyone else is saying!
hope it goes as easy as everyone else is saying!
08-21-2017, 12:30 AM
#100
OH. update. yeah, the WP is probably one of the easiest things ive changed on any vehicle 
BUT having to do everything else related to it that needed change, made it quite a bit longer. Mainly- that dumb plastic drain valve on the rad. broke and spun and spun. quit for the night and read up AFTER the fact. so i dug it ouuut in the morn and went to napa to get the 'ford/gm' valve and popped it in.
driving again with no problems!
BUT having to do everything else related to it that needed change, made it quite a bit longer. Mainly- that dumb plastic drain valve on the rad. broke and spun and spun. quit for the night and read up AFTER the fact. so i dug it ouuut in the morn and went to napa to get the 'ford/gm' valve and popped it in.
driving again with no problems!
11-11-2017, 04:58 PM
#102
Registered User
Somebody tell me the trick to the friggin radiator drain petcock! Water pump took 30 minutes, and I've fooled with the drain plug for an hour! It won't close.....just turns and clicks. Can the petcock be replaced?
11-11-2017, 06:24 PM
#103
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11-11-2017, 07:04 PM
#105
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