With pointers from others who posted to this forum I worked out a relatively easy way to change the crank sensor in my 94 Ram 2500 5.9. Like so many things, the key is the prep, and this is where the tips were useful.

I began by placing a 2x8 sheet of 3/4 ply across the front of the engine bay and a foam pad on top (I expected to be there awhile). I then removed the air cleaner components, put a rag of the throttle body intake, removed the spark plug wires on the even bank (passenger side)(tip 1), tied aside various vacuum lines and the heater hose such that I had relatively clear access to the area behind the valve cover and auto transmission fill/check tube (tip 2). Then I removed the exhaust heat shield attached to the firewall (tip 3). I used a 1/4" ratchet, extensions, universal and 13 mm deep well on the 3 nuts. I removed the nuts from under the truck but wiggled the heat shield up and out from the top (putting it back the same way). From below the truck I could see the bolts holding the sensor but could not get enough hand up there to do anything, but I was able to determine their approximate angle relative to the valve cover and see that they were positioned under the EGR tube that runs from the back of the head to the block. This EGR tube has a dip or kink in it that bends toward the block in the middle. The crank sensor bolts (mine are 5/16 x 3/4 x 1/4" allen) are under the more "open" portions of the EGR tube, one to the left side and one to the right side of the dip/kink.

The real deal, however, is the tool. I have attached 3 pictures. Img 1 shows the 6" long "wobble head" 1/4" allen wrench with a 3/8" drive. Img 2 shows the tool inserted in the bolt and the amount of deflection enabled. The 3rd image shows the way I used a small amount of electrical tape around the tool and head of the bolt to make insertion easier.

I lay on top of the foam padded plywood with my forehead on the exposed edge of the engine bay with the hood up. I was able to just feel the bolts with my left hand, going in just below the valve cover, over the EGR tube, and with my right hand going in just to the right of the valve cover. Using the tool shown it was easy to get it inserted into the bolt I wanted and a simple matter to break it free and remove it. Getting the sensor itself out took a bit of judicious wiggling, and unplugging the electrical connection (driver's side of the distributor, behind a bunch of other wiring) was a bit of a challenge.

Everything went back in quickly. The wobble head allen wrench allowed just enough displacement from dead square to get a firm insertion into the head of the allen bolts.

 

The heat shield nuts are 13 mm, not 12 mm. I was thinking 1/2" when I typed 12 mm.

 

Nice write up. What year truck? 94,95 (egr). And just edit the original post as far as the sizes go. And the year of the truck should be in the title(which I can fix). Then we'll see about adding it to the FAQ/DIY section.

 

It is a 94, 8' bed. Not in the title, but in the first line.

 

Yea I know the year is there, I didn't mean to add that extra question. I'll change the title to Replacement of crank sensor, 94 and 95. The newer ones don't have an EGR tube in the way, just the tranny fill tube. Also the newer one's have a multi bolt(for lack of a better word) allen and a socket head. Either way, I personally think it's a good write up, and I'll leave the thread open for now, for anyone that wants to add any pertinent info. More pics would be nice too.

 

Good writeup!!!!! That is a real world crank sensor exchange. That is one thing I have not replaced on my Ram as of yet but I do have one new in the box on the bench. Thanks

 

I happen to agree. Regardless of the slight year changes, it still has great info. Like I said, I'll leave it open (for now) so the info can be updated with other helpful tips.

 

an easier alternative... 3/8"-6" extension, universal, and a 1/4" allen socket. no need to remove any heat shields, wires, or vac lines. takes 5 minutes, out, 5 minutes in.

kinda got it down to a science, considering ive done it 6 times now, within the last 2 years. 4 of those within the last 2 week. haha