Here is a post from a guy that did it
WHOO HOO! Anybody want to drive my "New" truck!!!!
Happy to report that the pump is back together and running like a sewing machine. Much more power and no Dead Pedal! I have only about 10 miles on it so I will keep you advised if anything changes.
See my note above in post #11 that outlines the major problem. I think that is the lack of power and fuel economy issue. It may also be the dead pedal issue as well.
Now, I would not say it went totally without a hitch and the problems were self inflicted. If you are going to do it yur self, I will recommed a few things:
1, do not disturb the bronze ring on the main shaft. It is the reluctor for the timing pickup and controls the timing of the pump. I removed it and had to time it by trial and error.
2, Pay attention to the orientation of the parts as it is possible to get it 180 deg out of sync which I did the first time. There are no marks for alignment of the parts, so mark them upon disassembly to ensure proper re-assembly.
Hardest part of working on it are those darn tamper resistant torx screws and the fact that there are no manuals that I could find.
Parts: Bosch gasket kit (all orings) part# DGK138 from USDiesel in Ft. Worth TX (817) 485-6422 Mr. Brad Glenn. $37.88
If you have above average mechanical aptitude and a want to save $1500, then you can try this yourself. If i get time, I may put together a proceedure or you can e-mail me direct for my opinion and assistance. [email protected]
This may not fix a really screwed up pump, but it fixed mine. By the way, this was the original pump in my 2001 3500 with 195,000 miles and it was not worn out.