🔧 3500 - Water Pump Replacement

On your 3500’s 6.4L HEMI, the water pump circulates coolant through the engine and radiator. Replacing it usually involves draining coolant, removing the fan/shroud and belt, swapping the pump and gasket, then refilling and bleeding the cooling system.

Difficulty Level: Intermediate | Estimated Time: 2.5-4.5 hours

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⚠️ Safety & Precautions

• ⚠️ Let the engine cool completely before opening the cooling system.
• ⚠️ Hot coolant can cause severe burns—open the cap slowly with a rag.
• ⚠️ Keep hands/clothes away from the fan area; disconnect the battery to prevent accidental cranking.
• ⚠️ Support the truck securely if you raise it—never rely on a jack alone.
• ⚠️ Capture coolant in a drain pan; keep away from kids/pets.

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🔧 Required Tools

You'll need the following tools for this repair:

• Safety glasses
• Nitrile gloves
• Floor jack (rated 3-ton minimum)
• Jack stands (rated 3-ton minimum)
• Wheel chocks
• Drain pan (at least 4 gallons)
• Funnel
• Shop towels
• Plastic trim clip remover
• Flat-blade screwdriver
• Pliers
• Serpentine belt tool (specialty)
• Torque wrench (10–80 ft-lb range)
• Ratchet (3/8" drive)
• Ratchet (1/2" drive)
• Extensions (3" and 6")
• 8mm socket
• 10mm socket
• 13mm socket
• 15mm socket
• Fan clutch wrench set 36mm (specialty)
• Gasket scraper (plastic)
• Razor scraper (plastic-safe)

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Water pump - Qty: 1
• Water pump gasket / seal (if not included with pump) - Qty: 1
• Coolant (Mopar OAT, 50/50 premix or concentrate + distilled water) - Qty: 3-4 gallons (as needed)
• Distilled water (if using concentrate) - Qty: 2-3 gallons (as needed)
• Hose clamp(s) (optional, if clamps are weak or rusted) - Qty: 1-3

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📋 Before You Begin

• Park on level ground, set the parking brake, and chock the rear wheels.
• Let the engine cool fully (upper radiator hose should feel cool).
• Disconnect the negative battery cable using a 10mm socket.
• Set your drain pan under the radiator drain area before loosening anything.
• Take photos before removing brackets/hoses.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Remove the intake duct (for room)

• Loosen the clamps using an 8mm socket or flat-blade screwdriver.
• Unclip/remove the duct and set it aside.

Step 2: Drain the coolant

• Place the drain pan (at least 4 gallons) under the radiator drain area.
• Slowly loosen the coolant reservoir cap by hand to relieve pressure (only when cool).
• Open the radiator drain (if equipped) using pliers, or remove the lower radiator hose clamp using pliers to drain.
• After draining, reinstall/secure the drain or lower hose temporarily.

Step 3: Remove the fan shroud

• Remove the upper shroud fasteners using a 10mm socket.
• Use a plastic trim clip remover for any push-pins/clips.
• Lift the shroud slightly to free it (you’ll fully remove it once the fan is loose).

Step 4: Remove the mechanical fan and clutch

• Use a fan clutch wrench set 36mm (specialty) to loosen the fan clutch nut at the water pump pulley.
• Hold the pulley from turning per your wrench set design, then spin the fan/clutch off and lift it out with the shroud.
• Keep the fan vertical to avoid radiator damage.

Step 5: Remove the serpentine belt

• Rotate the belt tensioner using a serpentine belt tool (specialty) (this long handle helps in tight spaces).
• Slip the belt off one pulley and slowly release the tensioner.
• Note the belt routing (take a photo or reference the under-hood routing label).

Step 6: Disconnect hoses from the water pump area

• Remove the upper radiator hose from the pump/thermostat housing area using pliers.
• Remove any small bypass/heater hose at the pump using pliers.
• If a hose is stuck, gently twist it by hand—don’t pry on plastic fittings.

Step 7: Remove the water pump

• Remove the water pump mounting bolts using a 10mm socket (some locations may use a 13mm socket depending on pump design).
• Support the pump as the last bolts come out, then remove it from the timing cover.
• Clean the mating surface using a gasket scraper (plastic) and shop towels.
• Do not gouge the aluminum—use a razor scraper (plastic-safe) lightly if needed.

Step 8: Install the new water pump and gasket

• Install the new gasket/seal on the new pump (match orientation exactly).
• Position the pump and hand-start all bolts to prevent cross-threading.
• Tighten bolts evenly in a crisscross pattern using a ratchet (3/8" drive).
• Final tighten using a torque wrench (10–80 ft-lb range): Torque water pump bolts to 25 Nm (18 ft-lbs).

Step 9: Reinstall hoses, belt, fan, and shroud

• Reconnect hoses and position clamps using pliers.
• Reinstall the serpentine belt using the serpentine belt tool (specialty) and confirm it’s seated in every pulley groove.
• Reinstall the fan/clutch using the fan clutch wrench set 36mm (specialty) (snug firmly; it self-tightens in operation).
• Reinstall the shroud fasteners using a 10mm socket.
• Reinstall the intake duct clamps using an 8mm socket or flat-blade screwdriver.

Step 10: Refill and bleed the cooling system

• Close the drain (or ensure the lower hose is secured) using pliers.
• Fill the coolant reservoir with Coolant (Mopar OAT, 50/50) using a funnel.
• Reconnect the battery negative cable using a 10mm socket.
• Start the engine and set heat to HOT, fan on LOW.
• Let it idle and watch the temp gauge; top off coolant as the level drops.
• Once warm, verify the upper radiator hose gets hot (thermostat open) and check for leaks.

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✅ After Repair

• Inspect for leaks around the pump and all hose connections with the engine running.
• Verify the heater blows hot air (confirms coolant flow).
• After a full cool-down, recheck the coolant level and top off to the “FULL COLD” mark.
• Check belt tracking (should run centered on pulleys) and listen for squealing.
• Over the next 2-3 drives, recheck for seepage and recheck coolant level when cold.

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💰 DIY vs Shop Cost

Shop Cost: $650-$1,050 (parts + labor)

DIY Cost: $140-$320 (parts only)

You Save: $330-$910 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2.5-4.5 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.