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TECHNICAL SERVICE BULLETINS

1. i 2 Q Dd 5 X Q Yn 2 Q S BE ab pry 4 2 i av O To ae T 2012 1989 SERVICE BULLE TINS TECHNICAL Over the Years Dodge Technical Service Bulletins Not surprisingly there have been comments by those unfamiliar with the truck prospective new used buyers Internet truck shows that the Turbo Diesel certainly has its share of problems To them no doubt the grass looks greener on the other side Although some will dwell on the problems the majority of owners take initiative to solve correct anticipate prepare for a future situation That s what the TDR is all about Thanks to the TDR membership group and the support from DaimlerChrysler and Cummins we are equipped with answers and solutions rather than wonderment and isolation that would exist without a support group My thanks goes out to the TDR members for being a supportive membership group DODGE TECHNICAL SERVICE BULLETINS With the brief introduction out of the way this is our review of Dodge Technical Service Bulletins issued in the previous years For a given calendar year all Dodge vehicle TSBs are published in book format and are available for purchase in July August As a service we purchase the TSB directory and then search through the book for only those bulletins relating to the Turbo Diesel truck In an effort to consolidate the TSBs for the magazine we use the
2. Other drivability enhancements e EGR Valve cleaning and monitoring enhancements to help reduce occurrences of P049D STEERING CATEGORY 19 TSB MODEL 19 002 12 _03 04 DR 7 12 12 05 09 DH 06 09 D1 07 09 DC 10 12 D2 DJ DD SUBJECT DESCRIPTION The customer may experience steering wheel vibration typically while driving above 50 mph Vehicles equipped with a solid front axle 4x4 or cab and chassis trucks can be susceptible to steering shimmy Often this condition is due to modifications to the vehicle that may involve aftermarket equipment that may not be compatible with the vehicle architecture or is not intended for on road use For original equipment this condition can be corrected with routine inspection for properly maintained wheels and tires and replacement of damaged or worn components Troubleshooting of the problem begins with the verification of warranty coverage and discussion with the customer The technician is directed to test drive the vehicle to confirm the complaint Next a long series of inspections questions verifications and corrections are presented The following gives you an example of how the troubleshooting is done Is the vehicle equipped with aftermarket components or other modifications e g lift kits wheels suspension components or tires that can affect the performance of or wear upon steering components If the answer is yes the dealer is to notify the owner and docum
3. 06 DR 5 5 06 23 004 07 04 07 DR 01 26 07 23 021 06 07 DR Rev A 08 09 06 23 047 06 06 07 DR DH D1 10 21 06 23 010 07 06 07 DR DH D1 3 24 07 1500 2500 3500 23 011 07 06 07 DR DH D1 3 30 07 1500 2500 3500 23 013 07 02 07 04 13 07 DR DH D1 DC A Publication of the TURBO DIESEL REGISTER Speaker buzz Customers may experience a buzzing sound coming from the door area when the radio is on This bulletin involves adding insulating tape to the inner door and door trim panel Transit film removal This information only bulletin provides a transit film removal procedure YES Essentials stain odor and static resistant fabric care This bulletin applies to vehicles equipped with YES Essentials stain odor and static resistant fabric sales code XGW YES Essentials fabric is an easy care material that repels and releases soil to maintain the like new appearance Spills remain on the surface of the fabric to allow for easy clean up and to prevent stains and odors The material is antimicrobial and static resistant YES Essentials fabric may be cleaned in the following manner e Remove as much of the stain as possible by blotting with a clean dry towel e Blot any remaining stain with a clean damp towel e For tough stains apply Mopar Total clean p m 04897840AA or a mild soap solution to a clean damp cloth and remove the stain Use a fresh damp towel to remove the soap r
4. 91 93 AD with 7 23 93 automatic transmission 18 05 92 92 AD 6 15 92 18 06 92 91 92 AD 6 29 92 18 10 92 A 91 92 AD with 9 8 92 automatic transmission 18 11 92 91 92 AD 7 13 92 18 17 92 91 AD 9 8 92 18 18 92 91 92 AD 10 19 92 18 15 92 91 AD A Publication of the TURBO DIESEL REGISTER VEHICLE PERFORMANCE SUBJECT DESCRIPTION Diesel low power performance specs The bulletin applies to automatic transmission trucks with a customer complaint of slow acceleration or low power Performance tests 0 60 are performed and an acceleration table to reference is provided The bulletin guides the dealership through a series of trouble shooting tests to troubleshoot the low power complaint Checks for wide open throttle a low pressure fuel system check and finally an injection pump timing adjustment are described Lack of power harsh transmission shifts The bulletin applies to vehicles built before 10 28 93 and involves the replacement of the throttle control lever to ensure full throttle travel Also adjustment of the throttle position sensor is described Excessive White Smoke Low Power The bulletin involves a diagnostic check of the cooling system and starting instructions before verifying timing of the engine Manual transmission engines are set to 12 5 degrees top dead center Automatic engines should be set according to the engine data plate Poor perfo
5. A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION Rear axle trac loc chatter This bulletin supersedes 03 01 94 7 8 94 and applies to trac loc Dana model 60 70 and 80 axles The symptom is chatter while turning corners The bulletin involves draining and refilling the axle with new fluid and trac loc additive It is important that gear oil 4796517 and trac loc additive 4318060 be used Launch shudder vibration For 1992 1993 131 or 149 wheelbase trucks Describes repair procedure to adjust the pinion angle of the rear end to eliminate vibration or shudder in the 1 2 shift made at medium to heavy throttle This TSB does not address wheel hop that occurs with manual transmission trucks at start off Wheel hop is a function of driveline spring wrap up because of high torque being exerted on the pinion shaft CATEGORY 5 BRAKES TSB MODELS SUBJECT DESCRIPTION 05 09 95B_ 94 95 BR Drift left or right under moderate or hard braking 9 22 95 All 4x4 and 3500 4x2 The symptom is a drift right or left during moderate to hard brake applications just short of antilock Club Chassis only operation The condition is more evident with worn brakes The steering wheel remains straight ahead truck drifts The repair is not to correct a condition where the steering wheel moves during the drift If steering wheel moves a brake system inspection according to the service manual is in order The repair involves instal
6. P2170 02 Sensor 1 2 Out of Range High P2171 02 Sensor 1 2 Out of Range Low P241A 02 Sensor 1 1 and 1 2 Oxygen Concentration Mismatch P2609 Intake Air Heater System Performance Vehicles flashed to address the above codes should be driven and repair validated If code s return follow diagnostic procedures available in DealerCONNECT TechCONNECT The software also updates the ECU with other improvements A Publication of the TURBO DIESEL REGISTER Correct water in fuel WIF parameter ScanTool may report a code as stored even though the fault has been cleared by completing a significant number of drive cycles without a repeat occurrence Active codes not always displayed correctly Engine derate with IOD removed This will help prevent turbo damage due to oil thickening in cold climate start up on new vehicles in transit Scan tool readiness reporting issues Other drivability enhancements EGR Valve cleaning and monitoring enhancements to help reduce occurrences of P049D Erroneous brief brake lamp flash at key on Improve EVIC message regarding idle shut down Ability to read EGR valve gap an wiTECH CATEGORY 18 VEHICLE PEFORMANCE continued TSB MODEL 18 012 12 11 DJ D2 3 19 12 SUBJECT DESCRIPTION Diagnostic and system improvements This bulletin supersedes service bulletin 18 002 11 Rev B dated December 16 2011 This bulletin involves selectively erasing and reprogramming the engine control mod
7. number as follows Warren S in the 11 VIN position through April 4 1996 St Louis U in the 11 VIN position through March 23 1996 Lago Alberto M in the 11 VIN position through April 14 1996 Saltillo G in the 11 VIN position through April 14 1996 The repair involves installing a blower motor relay and overlay harness to remove the blower motor circuit from the ignition switch In addition the ignition switch and electrical connector must be inspected for damage and replaced if necessary Note to TDR subscribers the primary parts package for this repair does not include a replacement ignition switch assembly but rather provides a blower motor relay and overlay harness if necessary an ignition switch wiring pigtail clips screws washers etc to install the blower motor relay During the repair the ignition switch and associated connectors are to be inspected The technician is instructed to look for indications of melting or deformation specifically at terminals four and five Very few vehicles are expected to require ignition switch replacement A Publication of the TURBO DIESEL REGISTER Editor s note The title of the recall Ignition Switch Recall 875 leads one to conclude that the recall is to replace the ignition switch assembly As summarized from the dealer service instructions the recall has very little to do with the ignition switch but rather is focused on
8. 01 BR 03 02 01 A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION Exhaust manifold bolt retention straps This bulletin applies to vehicles equipped with a 24 valve diesel engine built on or between engine serial number 56419738 and 56777585 with a date of engine manufacture from January 01 1998 to September 22 2000 This information is available on the engine data plate which is located on the left side of the engine affixed to the side of the timing gear housing Vehicles that are used for extended heavy trailer hauling purposes may experience a loss of exhaust manifold bolt torque This condition may lead to exhaust gas blow by past the exhaust manifold gasket s and even loss of exhaust manifold bolts Anew exhaust manifold bolt retention strap has been released as a means of locking the outboard exhaust manifold bolts in place This will prevent bolt rotation and torque loss during the thermal expansion and contraction cycles of the exhaust manifold 4 Coy CATEGORY 9 ENGINE continued 09 001 01 1 19 01 09 003 01 5 4 01 09 006 01 08 24 01 To be determined CATEGORY 18 01 All 98 02 BR 98 02 BR Intermittent loss of oil pressure sensor ouput voltage This bulletin applies to 2500 3500 diesels with engine serial number 56744083 to 56809910 The output voltage of the oil pressure sensor may intermittently dropout This condition may cause the engine oil pressure
9. 06 DR 12 16 05 24 006 06 02 07 DR 8 9 06 A Publication of the TURBO DIESEL REGISTER Defrost door inoperative The defrost door may break at the pivot shaft causing inadequate travel The system may not completely close causing a lack of air discharge out the floor vents and full discharge from the defrost outlet This may be caused by a broken actuator stop on the heater A C HVAC hous ing The bulletin describes the repair procedure for replacing the defrost door and the lower half of the heater AC housing Mega Cab lack of air flow from rear seat heat duct This bulletin applies to 2006 Ram Truck Mega Cab built between 8 29 2005 and 8 31 2005 The rear seat actuator rod could become disconnected from the actuator lever causing the rear seat heater door to become inoperative This bulletin involves replacing the rear seat heat duct actuator lever A C cooling coil odor This bulletin involves inspecting for leaves and other foreign material cleaning and treating the cooling coil and housing Some vehicle operators may experience a musty odor from the A C system primarily at start up in hot and humid climates This odor may be the result of microbial growth on the cooling coil During normal A C system operation condensation bacteria and fungi growth begins and odor results If the operator describes or the technician experiences a musty odor when operating the A C system perform the appropriate repair procedur
10. 08 16 99 99 BR BE 6 11 99 08 17 99 99 BR 05 28 99 08 22 99 98 BR 07 02 99 08 28 99 00 BR 08 20 99 08 32 99 98 99 BR 10 01 99 08 37 99 94 00 BR 11 12 99 08 39 99 00 BR 12 10 99 A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION Radio interference to from two way radio receivers This bulletin supersedes technical service bulletin 08 06 99 dated March 5 1999 Customers may complain of intermittent poor reception on their two way radios This bulletin involves installing a RFI filter in series with the electric fuel pump motor Inoperative or intermittent remote keyless entry RKE transmitter This bulletin supersedes TSB 08 16 99 Dated May 28 1999 This bulletin applies to vehicles built prior to March 1 1999 It applies only to vehicles equipped with the new peanut shaped transmitters The problem discussed is an inoperative RKE transmitter This condition may be intermittent and will have similar symptoms to a dead transmitter battery This can be caused by a lost or intermittent contact between the battery terminal and the printed circuit board A transmitter repair kit containing a new case with an improved battery terminal has been released This bulletin involves replacing the RKE transmitter case Compass mini trip computers no longer need calibration during new vehicle preparation This information only bulletin applies to vehicles equipped with the compas
11. 2010 and November 30 2010 equipped with 9 amplified speakers w subwoofer sales code RC3 or 9 amplified speakers sales code RCZ This bulletin also applies to DJ and D2 vehicles built between July 15 2010 and February 28 2011 equipped with Premium I speakers sales code RCK The repair involves removing and replacing the amplifier Flash Intermittent no start or intermittent RKE function This bulletin applies to DD DJ and DP vehicles built before April 7 2011 equipped with remote keyless entry sales code GXM This bulletin involves flash reprogramming the wireless ignition node WIN with new software The service flash corrects the following conditions e Intermittent no start e Intermittent RKE The above conditions may be caused by a software lockup in the module The lockup condition may be cleared by removing the reinserting fuse M27 Flash reprogramming the WIN will correct these conditions Loss of communications with the hands free module HFM If there is a loss of the hands free module function the service bulletin involves performing a USB service flash of the hands free module Intermittent diagnostic trouble code P0201 Fuel injector 1 circuit open closed This bulletin applies to a small number of vehicles equipped with the Cummins engine built between March 1 2011 and March 11 2011 Suspect vehicles may intermittently set DTC P0201 Fuel injector 1 circuit open closed This bulletin involves replacin
12. AD 94 99 BR 94 99 BR 98 BR 98 BR 89 93 AD 94 99 BR 99 BR 99 BR Clicking rattling or ratcheting noise coming from the seat belt retractor This bulletin applies to all club cab vehicles both two door Club Cab and Quad Cab models built before March 5 1998 During normal operation the seat belt retractor on the vehicles listed above may emit a clicking rattling or ratcheting noise This noise may be caused by a solenoid that is energized and de energized to operate the retractor spool of the seat belt retractor assembly The solenoid is controlled by a Seatbelt Control Timer Module SCTM which unlocks the retractor when energized If your diagnosis determines and the owner feels that the noise occurs too frequently the SCTM on your vehicle may be too sensitive and should be replaced Installation of radio transmitting equipment This bulletin supersedes technical service bulletin 08 22 95 dated May 12 1995 This information only TSB is provided to assist in properly installing communication equipment in Chrysler vehicle This information should be given to any owner inquiring about installing radio transmitting equipment Airbag on off switches This bulletin supersedes technical service bulletin 08 17 98 Rev B dated September 18 1998 This information only bulletin is provided to identify the parts and procedures necessary to deactivate airbags authoriz
13. Generally the customer complains that the vehicle dies while driving When diagnosed there may or may not be Diagnostic Trouble Codes DTC present When DTCs are present there may be one or more of the following DTC PCode Description 124 P0234 Turbo boost limit exceeded 146 P0217 Decreased engine performance due to engine overheat condition 361 P0254 Fuel injection pump fuel valve current too high 363 P0251 Fuel injection pump mechanical failure fuel valve feedback circuit 364 P1689 No communication between ECM and injector pump module 375 P0602 ECM fuel calibration error The diagrams show the area where performance enhancing equipment is being connected into the outboard wire of the two wires that control operation of the metering solenoid in the pump Another type of device places a connector between the metering solenoid harness and the up per connector on the pump Telltale evidence can be seizure of the pump rotor and or cracked or overstressed pump cam ring The protective sleeve around the two wires may be rolled or cut back to gain access for connection Injection pumps that have been tampered with are not warrantable Fuel filter water separator drain valve restriction This bulletin applies to vehicles equipped with a 5 9L Cummins 24 valve diesel engine sales code ETC or ETH built before October 11 2002 The problem described is that when the fuel fil ter water separator drain valve is opened nothing comes out The
14. If you value your rights to warranty consideration leave the air intake system alone Prior to this TSB there was the 09 001 10 TSB Prior to these TSBs there was the K amp N story the short version being that testing was done on this filter in 1999 by Dodge and Cummins Prior to the test K amp N was the number two selling item at Geno s Garage After the test K amp N filters were no longer offered by Geno s However folks still want to know more as aftermarket advertising does an admirable job of selling these parts So if you need to help control exhaust gas temperatures due to the high horsepower you are making you should consider a cold air box and a multi layer filter The Geno s folks do sell a multi layer filter See TDR Issue 56 page 150 and Issue 59 page 130 for the cold air box story See TDR Issue 34 page 105 and Issue 77 page 56 for the K amp N story CATEGORY 14 FUEL SYSTEM TSB MODEL SUBJECT DESCRIPTION 14 004 11 03 09 D1 DH DR Heavy duty filtration Mopar retrofit or add on parts available 4 1 11 07 10 DC This bulletin applies to D1 DH DR vehicles equipped with a 5 9 liter Cummins engine built from 2003 model year and D1 DH DC vehicles equipped with a 6 7 liter Cummins engine built from 2007 5 model year Several fuel system add on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions The description of parts availab
15. Safety systems Vehicle modifications repair Any of the safety systems may be disabled by inadvertent damage to wiring or system components or by changing or modifying the location of a component Airbag on off switches This bulletin supersedes technical service bulletin 08 037 99 dated 11 12 99 This bulletin is provided to identify the parts and procedures necessary to deactivate airbags authorized by NHTSA Airbag deactivation is a customer pay procedure not covered under the provisions of the warranty The component parts are covered under the appropriate Mopar part warranty DaimlerChrysler Corporation is now offering airbag on off switches for the selected vehicles listed above The switches are packaged in a kit containing all necessary parts except as indicated and a detailed instruction sheet Under the National Highway Traffic Safety Administration s rule consumers will be authorized for on off switches by claiming they meet any of several criteria Airbag on off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter For more information concerning the authorization process and or the authorization letter call NHTSA s Auto Safety Hotline at 1 800 424 9393 We encourage the dealer to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization A Publication of the TURBO DIESEL REGISTER CATEGORY 9 ENGINE continued TSB MOD
16. TDR Staff
17. reducing the chance of valve sticking as well as improving cab heat warm up time Idle speed will slowly ramp up from 800 rpm to 1200 rpm when all of the following conditions are met Intake Manifold Temperature less than 60 C 32 F Coolant Temp is less than 60 C 140 F The transmission is in Neutral or Park The Service Brake pedal is not depressed Throttle 0 Vehicle Speed 0 mph A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE continued If intake manifold temperature IMT is less than 9 C 15 F three of the cylinders will be shut off upon reaching 1200 rpm creating a slight change in engine sound which is normal Thus the engine has to work to overcome the three dead cylinders This allows the engine to create increased heat in the cooling system allowing more rapid warm up Either feature will abort when any one of the following occurs The automatic transmission is placed in gear forward or reverse The service brake pedal is depressed Throttle position is greater than 0 Vehicle speed greater than 0 mph Coolant temperature is greater than 79 C 175 F CATEGORY 21 TRANSMISSION TSB MODELS 21 004 01 01 BR 02 16 01 SUBJECT DESCRIPTION Overdrive disabled to improve transmission reliability during cold temperature operation This bulletin applies to vehicles equipped with an automatic transmission where the vehicle was built on or between June 26 2000 and Dece
18. vehicles The drag link inner joint may fracture under certain driving conditions This could result in a loss of steering control and cause a crash without warning Also the steering damper bracket at the tie rod tube may loosen This could allow the bracket to slide on the tube and may cause increased vehicle turning radius Repair The steering linkage must be inspected and some steering linkage components may need to be replaced CALIFORNIA EMISSIONS RECALL K01 REPROGRAM ECM OBD READINESS Date May 2010 Models 03 DR Dodge Ram 2500 3500 Pickup Truck 06 07 DH D1 Dodge Ram 2500 3500 Pickup Truck 07 DC Dodge Ram 3500 Cab Chassis This recall applies only to the above vehicles equipped with a 5 9 liter diesel engine sales codes ETC and ETH anda California emission control system sales code NAE And to above vehicles equipped with a 6 7 liter diesel engine sales code ETJ and a California emission control system sales code NAE built through January 5 2007 The Engine Control Module ECM on the above vehicles may fail to accurately report diagnostic system information with some generic scan tools This may cause the vehicle to be rejected or fail an Inspection Maintenance Test also known as a Smog Check Repair The Engine control Module ECM must be reprogrammed flashed EMISSIONS RECALL J35 REPROGRAM ECM REGENERATION STRATEGY Date April 2010 Models 07 5 09 DH D1 Dodge Ram 2500 3500 Pickup Tru
19. 001 09 dated July 23 2009 This diagnostic process was developed for any drivability concern with the 6 7 liter engine Non drivability engine issues or engine cooling system issues are not in the scope of this process The process begins by identifying the customer s concern and applying it to one of the following symptoms MIL illumination Engine cranks but does not start or starts and immediately stalls Engine surges bucks runs rough no MIL Engine noise no MIL Excessive black smoke out exhaust no MIL Excessive white smoke out exhaust no MIL Excessive blue smoke out exhaust no MIL Once the data has been collected and analyzed the diagnostic process can continue The tests are designed to direct the service technician to the diagnostic path that leads to corrective actions that repair conditions that occur most frequently for that specific concern Engine systems and PTO enhancements This bulletin supersedes service bulletin 18 029 11 dated December 17 2011 Cab chassis trucks equipped with a 6 7 liter Cummins diesel have a number of software improvements available This latest Service bulletin will include Improvements to prevent unnecessary malfunction indicator lamp MIL illumination for P0524 Engine oil pressure sensor circuit low P051B Crankcase pressure sensor circuit range performance P20EE SCR NOx catalyst efficiency below threshold Bank 1 U010E Lost communication with diesel
20. 01 2005 The vehicle operator may experience extended engine crank time in cold ambient temperatures on vehicles equipped with manual transmissions This flash also provides the following enhancements Improved start times for manual transmission vehicles Improved automatic transmission shifting Engine fan is activated if the coolant temperature sensor fails e Enhanced battery charging This bulletin involves flash reprogramming the PCM Cummins with the software Flash DTC correction turbocharger protection and clutch durability improvement This bulletin supersedes technical service bulletin 18 005 06 Rev A dated April 26 2006 This bulletin applies to Ram trucks equipped with the 5 9L Cummins 24 valve diesel engine sales code ETH built on or after June 9 2005 through and including May 31 2006 The PCM software has been revised to address the following issues e AMIL may illuminate due to one or more of the following diagnostic trouble codes P0071 Inlet Air Temperature Sensor Rationality P0111 Intake Air Temperature IAT Sensor Rationality P0514 Battery Temperature Sensor Rationality P0191 Fuel Pressure Rationality Turbocharger durability improvement Implemented an engine speed limitation when cold to protect the turbocharger bearings e Clutch durability improvement Implemented a minimum engine speed limitation when launching vehicle from a stop to protect the clutch This bulletin involves selective
21. 03 2006 The customer may experience any of the following TIPM diagnostic trouble codes DTC s B166B Left Trailer Tow Lamp Control Circuit Low Trailer harness left lamp circuit is shorted to ground B166C Left Trailer Tow Lamp Control Circuit High Trailer harness left lamp circuit is shorted to battery voltage B178C Left Trailer Tow Lamp Control Circuit Over Current Trailer harness left lamp circuit is intermittently grounding B166F Right Trailer Tow Lamp Control Circuit Low Trailer harness right lamp circuit is shorted to ground B1670 Right Trailer Tow Lamp Control Circuit High Trailer harness right lamp circuit is shorted to battery voltage B166E Right Trailer Tow Lamp Control Circuit Over Current Trailer harness right lamp circuit is intermittently grounding B1667 Back Up Lamp Feed Low Trailer harness back up circuit is shorted to ground B2215 Front Control Module Internal TIPM An internal fault code counter has exceeded its limit of 250 counts and one or more electrical outputs controlled by the TOPM have been disabled P1277 Starter Control Circuit 2 Low TIPM The output feed current to the starter solenoid has exceeded the upper current limit of 75 amps This may result in a no crank condition DTC s B1667 B166B B166E B166F B178C and B2215 These DTC s indicate that a hard or intermittent short circuit to ground exists in the wiring of one or more of the trailer electrical harness ci
22. 04 12 Pickup 2500 3500 68026934AA wiring adaptor for use with kit 6808353AA and in the model years 04 5 07 A Publication of the TURBO DIESEL REGISTER CATEGORY 14 FUEL SYSTEM continued Editor s Comments HD filtration This is one of those been there done that TSBs We discussed the merits of this TSB and specifically the 6 7 liter and 5 9 liter Auxiliary Fuel filter in last issue s magazine Issue 77 pages 14 16 In the cost analysis conclusion part of the article closed by saying Ding ding ding bottom line what is the cost analysis The Mopar kit will cost about 450 From last issue my Fool Transfer Pump Boy Scout project for the 05 to current trucks cost 625 The Fool Transfer Pump Boy Scout project gives you better filtration and a redundant pump for fuel supply However its installation requires removal of the fuel tank Nonetheless for my peace of mind l Il spend the 625 and do the extra labor for the fool solution that I presented in Issue 76 Your decision A lot can happen in the 11 months from the beginning of a project to magazine in hand However continue to stand behind my decision to use the redundant FASS Platinum 08 95G fuel transfer pump and filter as wrote about in Issue 76 pages 16 21 CATEGORY 18 VEHICLE PEFORMANCE TSB MODEL SUBJECT DESCRIPTION 18 004 11 10 DJ D2 Diagnostic and system improvements Rev B This bulletin supersede
23. 15 F or below Vehicles equipped with automatic transmission coolers may experience a lack of fluid flow to the transmission due to restricted cooler lines In periods of extended driving transmission failure may result The bulletin describes the installation of a cold weather transmission cooler by pass kit Caution is needed as the kit decreases the cooling capacity of the transmission when driving in hot ambient temperatures and is not recommended Vibration or perceived engine miss The symtom is a vibration or perceived engine miss at approximately 1100 rpm as the torque converter clutch engages The condition occurs in fourth gear lock up at speeds between 42 to 48 mph Depending on year model the powertrain control module is either replaced or reprogramed Delayed transmission engagement torque convertor drainback The condition is delayed transmission engagement of 2 to 8 seconds at initial start up The problem is most noticeable after the vehicle has been parked for an extended period The bulletin describes the installation of transmission lines with a one way drainback valve Speed sensor oil seepage The bulletin describes how oil seepage can occur in the speed sensor area The repair is the installation of a speedometer adapter Servicing of 5th gear mainshaft nut on NV 4500 manual transmission The information only bulletin describes the replacement of the 5th gear main shaft nut with a new nut if the original nut has to be rem
24. 9L Cummins diesel engine The problem described is that the transmission operates normally through all ranges except fifth gear The 14 page bulletin describes the proper repair procedure BODY TSB MODELS 23 13 98 98 BR 5 8 98 23 16 98 98 BR 5 1 98 23 17 98 94 98 BR 5 1 98 23 35 98 94 99 BR 8 7 98 23 37 98 98 99 BR 8 21 98 23 58 98 99 BR 11 27 98 A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION Rear sliding window difficult to open will not remain latched and or leaks water past the lower run channel If the rear sliding window is difficult to open will not latch and or leaks water past the sliding rear window s lower run channel this bulletin describes the proper diagnosis repair Splash guards mud flaps discolored and or distorted due to proximity to tailpipe This bulletin applies to vehicles equipped with dual rear wheels Vehicles equipped with splash guards may experience discoloration and or distortion along the outside edge of the passenger side rear splash guard due to the proximity to the tailpipe If necessary a new tailpipe assembly is installed Center armrest driver side hinge cover broken If the center armrest upper inertia latch cover driver side hinge cover is broken the proper repair involves replacement of the hinge Door trim panel retainer clip attachment breakage when door trim panel is removed for service The bulle
25. BR CATEGORY 24 Repair procedure for fallout damaged paint Mopar Parts has released a new product Mopar Fallout Removal Kit p n 04882417 for correcting paint damage due to industrial fallout rail dust over spray and volcanic ash The Mopar Fallout Removal Kit does not use a compounding process or acid wash and is the current Chrysler preferred method for correcting fallout damage This product uses a clay polymer material and a liquid that are safer and better than other fallout removal methods AIR CONDITIONING TSB 124 01 96A 10 18 96 24 12 96 8 2 96 24 16 96 10 11 96 20 MODELS 94 96 BR 96 BR Vehicles assembled between 2 1 96 and 6 28 96 with a VIN code 3 as the first digit 95 96 BR With engine serial number 56230585 thru 56293178 or 45232867 thru 45360437 These engines were installed befor 6 1 96 SUBJECT DESCRIPTION Heater A C system changes mode to defrost when accelerating This bulletin supersedes TSB 24 01 96 2 2 96 The vacuum supply line to the Heater A C system may drop when accelerating or when speed control engages This may cause the vacuum motor to switch to defrost The repair involves the addition of a vacuum check valve to the vacuum system Water leaks from HVAC floor outlet onto floor Water may drain out of the HVAC floor outlets while operating the A C system The bulletin describes the diagnosis and repair procedure Vacuum system contaminated with engi
26. CD format used in automotive CD players When these CDs are used customers may encounter error messages skipping or delaminating of the labels which can cause an eject failure It is important to question whether these kinds of CD media are being used When customers encounter these symptoms check the system with a known playable CD The media may not be compatible with some automotive CD players Replacing or exchanging the CD player will not address these issues 08 16 00 94 00 BR Front door speaker buzz 04 28 00 The bulletin discusses a buss noise coming from the front door speaker s The noise may be more noticeable while listening to talk radio segments with deep male voices The repair procedure involves installing a urethane foam pad between the inner door panel and the door trim A Publication of the TURBO DIESEL REGISTER ELECTRICAL continued CATEGORY 8 08 17 00 99 00 BR 05 12 00 08 18 00 98 01 BR 05 12 00 08 23 00 98 01 BR 06 23 00 08 26 00 00 01 BR 09 29 00 Intermittent speaker operation static Intermittent operation static may occur in any or all speakers The bulletin applies to vehicles equipped with the Infinity sound system sales codes RBR RBN and RAZ built before October 1 1999 This repair involves installing new speaker kits on both right and left front doors and installing foam between the inner door trim panel and the door Radio I
27. D2 Fuel filler housing pops out of sheet metal 9 21 10 This bulletin applies to vehicles equipped with a single wheel rear axle only built before August 9 2010 The customer may notice that the fuel filler housing has popped out from the body on one side or the other This bulletin involves removing the fuel filler housing to file some material off of the tabs that will not lock into place If tab s are broken it will be necessary to replace the fuel filler housing and it still may be necessary to file some material off of the tab s that will not lock into place CATEGORY 18 VEHICLE PEFORMANCE 18 004 11 10 DJ D2 Diagnostic and system improvements Rev A This bulletin applies to trucks equipped with a 6 7 liter Cummins diesel The bulletin describes a 2 18 11 number of software improvements enhancements that are available P046C EGR position sensor performance e P051B Crankcase pressure sensor circuit range performance e P0101 Mass air flow sensor A circuit performance e P2002 Diesel particulate filter efficiency below threshold e P2196 O2 sensor 1 1 out of range low e P245B EGR cooler bypass status line intermittent e P2262 Turbocharger boost pressure not detected mechanical P2271 O2 sensor 1 2 out of range low This bulletin involves selectively erasing and reprogramming the engine control module ECM with new software 2 A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICL
28. Do not install or have class suppliers install 1999 or earlier windshields on 2000 model year subject model vehicles Likewise do not install or have glass suppliers install 2000 or later windshields on earlier models Instrument panel creak A creak or squeak may be present near the left and or right side s of the instrument panel The noise is caused by the sheet metal joint between the A pillar and the dash pOanel plenum lower rubbing together The repair involves loosening that instrument panel and providing additional clearance between the A pillar inner panel and dash panel Paint foggingWwhitening Painted surfaces of the vehicle that are covered for extended periods of time with front end covers bras transit films or magnetic signs may appear to have a white milky spot on dark colors or a fogging coffee colored spot lighter colors The repair involves removal of a fogging or staining condition from any painted surface where moisture may be trapped under the clear coat by using a heat gun A Publication of the TURBO DIESEL REGISTER TSBs Issued During 2001 CATEGORY 2 FRONT SUSPENSION TSB MODELS 02 001 01 94 01 1 19 01 CATEGORY 5 SUBJECT DESCRIPTION Rear of vehicle sits too high to allow hook up to a fifth wheel trailer This bulletin applies to 2500 and 3500 4x4s The curb hight lowering package is designed to reduce the rear spring spacer block by 1 7 8 inch which will lower the rear of the vehi
29. ETJ built on or before February 14 2008 This bulletin discusses the G30 recall and the many drivability issues that are addressed and covered in the G30 recall software update Engine system and exhaust aftertreatment system enhancements This bulletin applies to vehicles equipped with a Cummins 6 7 liter engine sale code ETJ built on or before November 27 2008 This bulletin supersedes technical service bulletin 18 013 08 dated March 13 2008 This bulletin involves verifying that Emission Recall G30 Replace Oxygen Sensor Module and Reprogram ECM has been performed If not perform Recall G30 first then verify the software level and if necessary selectively erasing and reprogramming the Engine Control Module ECM with new software Additionally verify the software level and if necessary selectively erasing and reprogramming the Cab Compartment Node CCN module with new software With this latest ECM software release listed in this Service Bulletin the following symptoms have been completely addressed One of the following driveability conditions a An intermittent rough engine idle and or white smoke following initial engine start b Athrottle tip in stumble at engine speeds of 1 300 to 2 100 rpm c Anengine hesitation at altitude of 5 000 feet between engine speeds of 1 200 to 1 600 rpm d Aturbocharger chuff like sound during rapid deceleration e The vehicle may fail an Emission Inspection Maintenance I M Test beca
30. PCM software has been implemented to improve transmission reliability The customer should be informed that reduced fuel economy would be expected when overdrive is not in use The repair involves selectively erasing and reprogramming the Powertrain Control Module PCM with new software calibration level 01Cal14 NV5600 Countershaft service This bulletin involves Ram trucks manufactured prior to March 17 2001 and equipped with the NV5600 6 speed heavy duty transmission Customers may experience a shifter vibration commonly referred to as gear clash of the shift knob when shifting from one gear to another between 2500 and 3500 RPM after a cold start up This condition is most evident when ambient temperatures are at or near 0 C 32 F but can occur at warmer temperatures as well The condition is most often reported on 3 to 4 gear shifting but can occur in the other shift ranges as well The problem can be verified by assuring the transmission is at ambient temperature vehicle moving and with the engine at 2500 to 3500 RPM shifting into and out of the gear ranges This repair may include disassembly of the countershaft assembly requiring the use of a 20 ton press Attempts to use lesser equipment to effect this repair could result in damage or injury If such a press is available rebuilding the countershaft assembly is preferred In the event a press is not available a new countershaft assembly PN 05073361AA has been made
31. TPS or Alternator This bulletin involves selectively erasing and reprogramming the Powertrain Control Module PCM with new software calibration changes 98cal12 and 99cal14 Erroneous MIL illumination with DTC A8 P1763 governor pressure sensor volts too high This information applies to vehicles equipped with a reseries automatic transmission built before December 18 1998 Some vehicles may exhibit a MIL illumination with DTC A8 P1763 GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH The vehicle operator may experience slower than normal accelerations because the transmission may temporarily enter third gear Limp In Mode The Limp In Mode may last until the vehicle owner cycles the ignition key The technician may not detect a problem with the automatic transmission during a diagnostic test A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE continued 18 08 99 98 99 BR 04 30 99 18 09 99 99 BR 05 21 99 18 11 99 98 99 BR 05 28 99 18 21 99 98 99 BR 18 24 99 00 BR 11 15 99 A Publication of the TURBO DIESEL REGISTER or test drive The MIL is caused by an increase in hydraulic pressure The increased hydraulic pressure is the result of a new valve body machining process Vehicles built after January 1 1998 have an automatic transmission with this new process valve body Vehicles built before January 1 1998 may experience this condition if either the tran
32. The diagnosis involves using a spring scale to determine turning force The repair involves performing a ball joint tightening Low power assist in cold ambient temperatures The condition can be minimized by reviewing the cold start procedures Cold climate power steering fluid pn 04778524 may be used Steering Column coupler Arepair package with a revised boot has been developed to service the steering coupler The part number is 4740761 This is an information only bulletin Steering wheel off center Due to a shift in the steering gear bracket in high load conditions the steering wheel may be off center during straight driving The repair involves installing a shoulder bolt that acts as a dowel pin locking the steering gear bracket to the frame TRANSMISSION TSB MODELS 21 02 95 95 BR 3 31 95 built after 3 20 95 21 03 95 A 94 95 BR 6 16 95 21 04 95 94 95 BR trucks 4 14 95 with automatic transmission 21 05 95 A 94 95 BR trucks 1 5 96 with automatic transmission 21 08 95 94 95 BR 1 30 95 21 09 95 94 95 BR trucks 6 30 95 with manual transmission SUBJECT DESCRIPTION Quick connect removal and reconnect procedure The bulletin is an information only bulletin outlining two ways to disconnect the quick connectors of the automatic transmission lines Automatic transmission cold temperature cooler bypass kit The condition occurs at ambient temperatures of
33. a normal shift schedule to a tow haul mode shift schedule and allowed 4th gear overdrive gear engagement This new transmission feature will not change the transmission shift schedule but will allow full 4th gear overdrive disable lock out With this new feature the customer will have the normal shift schedule with NO overdrive 4th gear This bulletin involves selectively erasing and reprogramming the Cummins Engine Control Module ECM with new software 48RE Transmission 1 2 shift hunt at light throttle The customer may experience a 1 2 shift transmission hunt during light throttle application This condition may be due to a governor pressure solenoid valve This bulletin involves the replacement of the governor pressure solenoid valve in the transmission valve body CATEGORY 21 TRANSMISSION continued 21 014 07 All 21 019 07 07 08 DH D1 11 14 07 2500 3500 21 021 08 95 02 BR BE 9 17 08 07 09 D1 DC 02 09 DR DH Automatic transmission fluid usage ATF 4 Type MS9602 This bulletin supersedes technical service bulletin 21 010 06 dated 4 16 06 ATF 4 type 9602 is being used as factory fill for Chrysler Group automatic transmissions ATF 4 is recommended for all vehicles equipped with Chrysler Group automatic transmissions except for those noted Sprinter transmissions Crossfire transmissions MK PM vehicles equipped with Continuously Variable Transmission CVT all vehicles equipp
34. adding a relay to the blower motor circuit The moral of the story don t jump to conclusions based on the title of a memo and be sure additional trailer light wiring and accessories that are added to your vehicle are on a separate relay switched circuit FUEL TRANSFER PUMP RECALL 878 The fuel transfer lift pump on about 12 000 24 valve vehicles may be susceptible to premature internal armature shaft bushing wear Failure of the shaft bushing typically causes a no start condition To correct the problem the supplier of the fuel transfer pump Federal Mogul has returned to the original sintered iron bushing design The suspect vehicles have a Cummins engine serial number sequence that falls between 56662576 and 56671920 These engines were installed at the DaimlerChrysler assembly plant in St Louis from 12 3 99 to 1 18 00 Lago Alberto from 12 2 99 to 2 1 00 Satillo from 12 2 99 to 2 1 00 The replacement involves removal of the starter motor to gain access to the electronic transfer pump Remove and install a replacement pump Reinstall the starter and check for leaks and proper operation The flat rate time schedule for replacement is approximately one hour THROTTLE CONTROL CABLE AND THROTTLE LINKAGE REPLACEMENT SAFETY RECALL 970 DaimlerChrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1994 through 1996 model year Dodge Trucks equipped with a Cummins Turbo Diesel en
35. bulletin describes the repair procedure and parts needed to correct the problem 05 05 91 90 91 AD Front disc brake noise from Bendix disc brakes 8 12 91 The bulletin applies to trucks with Bendix disc brakes 3 38 caliper pistons Noise can occur and the repair involves grinding a chamfer on both ends of the outboard brake pad 05 07 90 89 90 AD Rear wheel anti lock faults caused by water contamination 9 24 90 A possible cause for illumination of the BRAKE and ANTILOCK warning lamps could be water contamination of the 4 way connector at the hydraulic valve and or at the 50 way connector The bulletin describes the repair and parts necessary to add a service jumper harness to the existing harness CATEGORY 6 CLUTCH TSB MODELS SUBJECT DESCRIPTION 06 01 94 89 93 AD with Transmission noise below 1400 rpm 8 12 94 manual transmission The bulletin describes a powertrain induced cyclic noise condition that appears to be transmission driveline related Especially noticeable in 4th and 5th gears the noise occurs below 1400 rpm during coast or light throttle The noise is not damaging to the powertrain and is due to the dampening characteristics of the clutch springs The revision if needed involves replacement of the clutch disc Transmission noise below 1400 rpm A Publication of the TURBO DIESEL REGISTER CATEGORY 6 CLUTCH continued 06 01 90 A 12 31 90 89 91 AD with manual transm
36. bulletin outlines the procedure for purging fluid out of the filter Electronic fuel control EFC actuator available for service This bulletin deals specifically with an engine surge at idle condition The diagnostic procedures are the same as those listed in TSB 14 003 05 The bulletin describes the repair procedure for replacement of the electronic fuel control actuator Cummins diesel diagnostics This bulletin applies to vehicles with the 5 9 liter engine sales code ETH or ETC Revised diagnostic procedures are available for the following conditions Engine cranks for a long time or will not start e White smoke and or misfire after starting when the engine temperature is below 150 F Engine surges at idle e Engine sounds The 12 page bulletin gives the service technician a set of revised diagnostic procedures for the fuel system Each condition is discussed and possible causes are established Step by step instructions help the technician identify and repair the problem 5 9 liter and 6 7 liter Cummins diesel engines correct low and ultra low sulfur highway diesel fuel use This bulletin involves a discussion regarding the correct diesel fuel to use for either the 5 9 liter or the 6 7 liter Cummins diesel engine sales code ETH and ETJ respectively Dodge Ram trucks equipped with the 6 7L Cummins Turbo Diesel engine are required by Federal law to be fueled with ultra low sulfur diesel fuel model year 07 5 Early production 20
37. dipstick The incorrect Cummins P N is 3944594 The problem is corrected with the installation of a revised dipstick 05014562AA Cummins 3935648 CATEGORY 11 EXHAUST TSB MODELS SUBJECT DESCRIPTION 11 08 98 94 98 BR Turbo Diesel wastegate actuator repair kit 9 25 98 A new kit has been released that will allow technicians to repair turbochargers with failed wastegate actuators CATEGORY 14 FUEL TSB MODELS SUBJECT DESCRIPTION 14 01 98 98 BR High pressure fuel line service Rev A This bulletin supersedes technical service bulletin 14 01 98 dated March 6 1998 This information 7 17 98 applies to the 5 9L Cummins electronically injected 24 valve diesel built prior to engine serial number ESN 56462592 Design revisions have been made to the injector connector tube and the new design can be re torqued multiple times without compromising the seal between the connector tube and high pressure fuel line The new part number for this connector tube is 05013856AA Cummins 3944833 14 02 98 98 BR Fuel filter requirements 3 27 98 With the introduction of the Cummins 24 valve electronically injected engine a new VP44 injection pump was also introduced The VP44 injection pump requires finer fuel filtration due to tighter tolerances within the pump Whenever a fuel filter is replaced make sure the replacement filter is part number 04883963AB Cummins 3931476 Fleetguard FS19528 14 04 98 98 BR Accelerator pe
38. driver side power seat may have a seat belt buckle that may be difficult to latch The repair involves replacement of the seatbelt buckle Tailgate difficult to close in cold weather At less than 5 F the tailgate latch stop bumper may be too stiff to allow for easy closure Inspect and replace bumper stop Windnoise whistle around grille area If vehicle exhibits a windnoise whistle at speeds of 45 to 85 mph the diagnosis involves checking the grille for a manufacturing code CAV3 If there is not a CAV3 stamp than the grille is not likely the source of the noise If noise is from the grille the repair involves adding 1 4 foam tape between the grille and hood Tailgate cracking on top inner ends Some vehicles may exhibit a sheet metal crack along the top inner ends of the tailgate The bulletin describes the parts and the correct repair procedure Instrument panel creak This bulletin supersedes TSB 23 57 93 8 8 93 A creak or squeak may be present on the left or right side of the instrument panel The noise is caused by two sheet metal parts rubbing together The repair involves loosening the instrument panel and providing additional clearance between the cowl and instrument panel support joint Rattle in door area Inspect the area of the door latch face around the lower window channel retaining bolt If necessary perform the outlined repair procedure 19 CATEGORY 23 BODY continued 23 69 96 11 22 96 97
39. e Any oven cleaner Any abrasive metal cleaner e Chrome polish unless it is buffed off immediately after application e Any abrasive cleaning pad or brush e Acar wash that has carbide tipped wheel cleaning brushes A Publication of the TURBO DIESEL REGISTER CATEGORY 23 BODY TSB 23 027 01 9 21 01 23 034 01 11 30 01 MODELS 98 02 BR BE Equipped with 6x9 Mirrors Sales Code GPS or GPU 00 01 BR BE SUBJECT DESCRIPTION Outside rearview mirror glass replacement This bulletin supersedes technical service bulletin 23 034 00 Rev A dated December 15 2000 It is unnecessary to replace the entire outside rearview mirror assembly when the mirror glass is broken or is missing Replacement mirror glasses are available from Mopar Because of the extremely long list of part numbers involved please consult the Mopar parts catalog for the correct part number s Scratching sound from the door seal while driving A scratching or itching type sound may be heard coming from the front door opening If a customer indicates that the condition is present perform the repair procedure which involves lubricating the secondary door seal with part number 04773427 Weather Seal Lubricant CATEGORY 25 TSB 25 001 01 1 19 01 25 002 01 1 19 01 A Publication of the TURBO DIESEL REGISTER MODELS 01 BR BE 01 BR BE EMISSIONS SUBJECT DESCRIPTION Generic Scan Tool May Not Display Certain DT
40. exhaust fluid control unit P2609 Intake air heater system performance P061A ETC level 2 torque performance P1123 Power take off system monitor control error P2579 Turbocharger speed sensor circuit performance Enhanced diagnostics for Variable geometry turbocharger Fuel level sensor Misfire without MIL illumination Other updates Low diesel exhaust fluid DEF level EVIC messaging strategy changes Diesel Exhaust fluid DEF system tampering EVIC messaging strategy changes Oil change monitor updated for easier reset same basic procedure easier to reset Scan tool display updates Enable mobile PTO capability Correct operation of remote PTO Correct EVIC messaging related to DEF level reporting System robustness improvements DEF tank level reporting erroneously at high DEF tank level When DEF tank is overfilled the EVIC may display low fluid level 20 22 This bulletin involves selectively erasing and reprogramming the engine control module ECM with new software A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PEFORMANCE continued TSB MODEL SUBJECT DESCRIPTION 18 001 12 12 DD DP Engine systems and PTO enhancements RevA This bulletin supersedes service bulletin 18 001 12 dated January 07 2112 Cab chassis trucks 1 28 12 equipped with a 6 7 liter Cummins diesel have a number of software improvements available This latest service bulletin will include Improvements t
41. glycol instead of ethylene glycol coolants CATEGORY 8 ELECTRICAL TSB MODELS SUBJECT DESCRIPTION 08 01 97 96 97 BR JTEC powertrain control wiring harness connector repair packages 2 3 97 If a dealership determines that a powertrain customer complaint could be related to a poor electrical connection the PCM connectors should be inspected The bulletin describes an assortment of electrical connector and terminal repair components that are available to aid in powertrain electrical wiring repairs 08 21 97 94 97 BR Engine failed to crank no start 5 23 97 This information only bulletin discusses a condition where the engine does not crank over when the ignition is placed in the start position The shop should then refer to the appropriate 97 Service Manual for proper diagnosis of the starter motor s electrical circuit A Publication of the TURBO DIESEL REGISTER x CATEGORY 8 ELECTRICAL continued 08 22 97A 7 11 97 08 27 97A 9 26 97 08 30 97 9 5 97 08 32 97 9 19 97 08 35 97 9 26 97 08 39 97 11 28 97 CATEGORY 11 96 97 BR 97 BR 98 BR 94 98 BR 98 BR 98 BR Inoperative speed control This bulletin supersedes TSB 08 22 97 dated 6 20 97 The problem covered by the bulletin is an inoperative speed control due to a vacuum supply hose that is loose leaking or deteriorated Using the diagnosis as outlined in the 97 Service Manual determin
42. illumination for PO40B EFR Temperature Sensor 1 Circuit Performance e An erroneous MIL illumination for P0405 EFR Position Sensor Circuit Low This bulletin involves selectively erasing and reprogramming the Engine Control Module ECM with new software CATEGORY 19 STEERING TSB MODELS 19 003 02 97 02 BR BE 4 15 02 19 005 03 94 02 BR BE 8 29 03 02 04 DR A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION Hissing sound coming from the power steering system on vehicles equipped with hydroboost brakes A hissing sound may be present in the power steering system during steering maneuvers or straight ahead driving This bulletin involves replacing the power steering hoses connecting the hydroboost to the power steering pump and gear Power steering fluid usage The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF 4 part number 05013457AA S9602 and it provides superior performance at both low and high temperatures Refer to the table to identify factory fill and the approved service power steering fluid by year and model From the table it is noted that the 94 to 02 truck uses part number 04883077 MS5931 MS9602 should not be mixed or used as a topping off fluid on systems requiring MS5931 67 CATEGORY 19 STEERING continued 19 008 03 03 DR Vibration in steering column 11 28 03 Avibration may be felt in the steering wheel and or
43. is the new WIF DTC that has been added DTC P0169 WIF Too Long Error Improvement to the fuel pressure rationality test to prevent false test failures and the related DTC 0191 This bulletin involves selectively erasing and reprogramming the engine control module with new software Flash DTC P0471 Exhaust pressure sensor rationality on Cummins 6 7 liter Turbo Diesel This bulletin applies to vehicles equipped with a 6 7 liter engine sales code ETJ built on or before October 05 2006 The vehicle operator may experience a malfunction indicator lamp MIL illumination due to diagnostic trouble code DTC P0471 exhaust pressure sensor rationality This bulletin involves selectively erasing and reprogramming the engine control module ECM Cummins with new software Flash check gauges lamp illuminates for alternator charging with DTC P2502 P2503 or P2509 This bulletin applies to vehicles equipped with a 5 9 liter engine sales code ETH built on or before November 29 2006 The customer may experience the illumination of the Check Gauges lamp on the instrument panel cluster Inspection of the gauges may reveal that the battery charging gauge may read in the 11 volt range rather than in the 14 volt range There may not be a Check Engine Malfunction Indicator Lamp MIL illumination Further diagnosis may reveal the following diagnostic trouble codes DTC s have been set P2502 Charging System Error Diesel P2503 Cha
44. not remove the anti friction tape Instrument panel creak A creak or squeak may be present on the left side of the instrument panel The repair involves loosening of the instrument panel to provide additional clearance between the cowl side panel and instrument panel support joint Tailgate rattles If tailgate rattles over bumps check for looseness If tailgate does not close tightly replace the overslam and alignment bumpers 93 standard paint colors 92 standard paint colors 91 standard paint colors 90 standard paint colors 89 standard paint colors AIR CONDITIONING TSB MODELS 24 01 95 A 89 94 AD 3 3 95 24 06 95 A 94 95 BR 5 26 95 24 08 95 94 95 BR 5 19 95 24 08 94 94 BR 5 6 94 14 SUBJECT DESCRIPTION R 12 to R 134a refigerant adaptation procedure The bulletin describes the conversion from R 12 to R 134a The procedure should only be performed on vehicles when R 12 is no longer available Odor from air conditioning ducts Some vehicles may emit a musty odor from the airconditioning ducts The odor is most noticable when the A C system is first turned on Two possible causes are discussed and repair procedure are outlined based on less than or greater than 12 months in service White flakes from instrument panel outlet Sodium silicate is used to coat the air conditioner evaporator for corrosion protection If excessive amounts are appli
45. oil change intervals No additive is known to be safe for engine durability and they can degrade emission components Additives can contain undesirable materials that harm the long term durability of engines Generally it is not desirable to mix additive packages from different suppliers in the crankcase there have been reports of low temperature engine failures caused by additive package incompatibility with such mixtures Engine lubricant This bulletin involves 1989 2001 Ram trucks equipped with the 5 9L Cummins diesel engines This bulletin discusses the recommended oil filters for use with Cummins 5 9L diesel engine Part No Manufacturer 05016547AC Mopar LF3894 Fleetguard Stratapore LF3552 Fleetguard Microglass LF3959 Fleetguard Cellulose 3937695 Cummins Cellulose FL896 MotorCraft Cellulose L45335 Purolator Cellulose PF1070 AC Delco Cellulose The information only bulletin was issued to alert the field to problems caused by aftermarket oil filters For example neoprene compounds used internally in the manufacture of oil filters not recommended by DaimlerChrysler may separate from the filter lodge in the piston cooling nozzle and cause the engine to fail THIS IS NOT AN ENGINE DEFECT Engine Oil Pan Gasket Sealing This bulletin applies to Ram trucks equipped with the 24 valve diesel engine Repeated oil pan gasket leaks can occur on 24 valve diesels if the gasket is applied without the use of Mopar Silicon Rubber Adhesive RTV
46. or phosphoric acid Any abrasive type cleaner A Publication of the TURBO DIESEL REGISTER CATEGORY 22 WHEELS amp TIRES continued 22 005 06 10 07 06 22 002 07 Rev A 7 12 07 03 07 DR DH D1 DC 08 DH 2500 CATEGORY 23 e Any abrasive cleaning pad such as steel wool or abrasive brush Any oven cleaner e Acar wash that has carbide tipped wheel cleaning brushes Front end shimmy on 4x4 vehicles when traveling over rough surfaces in the road This bulletin applies to four wheel drive 4x4 2500 and 3500 model vehicles The customer may experience a self sustaining vibration shimmy felt in the front end of the vehicle after striking a bump or pothole This bulletin involves verifying the condition of the vehicle front suspension and steering components and adjusting the front tire pressure If the customer experiences the above condition perform the repair procedure which includes a steering damper tie rods and end links Tire pressure monitor system TPMS Light Load reset switch and tire rotation caution This information only bulletin provides information for new vehicle preparation setting tire pressures rotating tires and setting the light load switch on vehicles with the tire pressure monitoring system installed BODY TSB 23 018 02 5 20 02 23 018 03 6 13 03 23 016 03 6 13 03 23 025 03 10 24 03 23 001 04 1 13 04 A Publication of the TURBO DIESEL REGISTER M
47. or secondary door seal may become torn from contact with the lower A pillar of the front door The repair involves replacing the secondary door seal with an improved seal Water leak at roof mounted marker lamps Water leaks may be present coming from the roof mounted marker lamps New marker lamps have been released which contain base gaskets These marker lamps should be used in all cases where water leaks are present at the marker lamps These lamps will have to be replaced in sets of five due to appearance differences If water leak tests reveal that water leaks are present at the marker lamps perform the repair procedure Windshield wiper blade maintenance Windshield wiper blades elements are frequently replaced unnecessarily If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades elements is obvious the following steps should be performed e Use a soft cloth or sponge and squeegee and a solution of 50 50 alcohol and water to wash the windshield e Raise the wiper blades off the glass and clean the wiper blade elements with a solution of 50 50 alcohol and water and a soft cloth paper towel or sponge e Return the wiper blades to their normal operating position If the wipe pattern is still objectionable repeat several times If the wipe pattern is still objectionable replace the wiper blades elements A Publication of the TURBO DIESEL REGISTER CATEGORY 23 BODY continued 23 018 06
48. revised brake linings The bulletin discusses wear conditions The repair procedure involves replacing possibly the front brake linings rear brake linings or rear wheel cylinders depending on truck model and vehicle sales code Brake pedal rattle If a rattle is heard coming from the brake pedal area and is eliminated when pressure is applied to the side of the brake pedal a repair procedure involving a wave washer is outlined Brake noise The information only bulletin describes the normal noises that may occur with a properly operating system ABS self check trace squeak grinding groaning etc noises are discussed Chassis dynamics diagnosis The bulletin discusses conditions where by the vehicle may move to the right or left when not controlled by the driver Several causes are cited aftermarket wheels road crown cross winds incorrect tire pressures worn wheel bearings etc Diagnosis involves testing the vehicle to determine if the drift is brake related A brake system evaluation is outlined Steering and suspension inspection is discussed Suspension torque values for fasteners are discussed A suspension geometry evaluation is outlined Front end alignment specifications are provided Wheel shim kits and installation of shims for 4x4 trucks is discussed ELECTRICAL TSB MODELS 08 20 96 96 97 BR 7 19 96 08 21 96A 96 BR 10 18 96 08 23 96 94 96 BR 8 23 96 built prior to 12 15 96 08 33 96 94
49. same index system categories as DaimlerChrysler Below are the index categories 2 Front Suspension 3 Rear Axle 5 Brakes 6 Clutch 7 Cooling 8 Electrical 9 Engine 11 Exhaust 13 Frame amp Bumpers 14 Fuel 16 Propeller Shafts amp U Joints 18 Vehicle Performance 19 Steering 21 Transmissions 22 Wheels amp Tires 23 Body 24 Air Conditioning 26 Miscellaneous A note concerning the TSBs and their use the bulletins are intended to provide dealers with the latest repair information Often the TSB is vehicle identification number VIN specific VIN data on the Chrysler service network helps the dealer in his service efforts A TSB is not an implied warranty TABLE OF CONTENTS Technical Service Bulletins 1989 1995 TSB 0 ecccceeeeeeeeees 1996 TSB ceia IETA silence TAOS TOB onena aina TOUN TOB aiaiai aa 2000 TSB ities Gi ieee 2001 TSB eit esedeciterieheneslenlaiieess 2UU2 TOB oiana 2003 2009 TSB eccaoin 2010 TOB ei aa 201 TSB unei i AE E EEE Recalls 1997 2009 Recalls ceee 2012 REGAINS ois ccceeccinssteeeasaunaceces A Publication of the TURBO DIESEL REGISTER TSBs Issued During 1989 1995 CATEGORY 2 FRONT SUSPENSION TSB MODELS 02 05 95 94 95 BR 5 15 95 4x4 4x2 Cab Chassis 02 02 94 94 BR 2 11 94 02 07 94 94 BR 6 15 94 02 08 94 94 2500 BR 7 22 94 Cab Chassis with sales code XBC 02 20 94 94 BR 12 2 94 02 02 91 92 AD 2WD 1 28 91 vehicles on
50. the cruise control is engaged This bulletin is for non intercooled build date prior to 1 1 91 trucks The bulletin involves replacing the vehicle speed control module with a recalibrated module Poor engine performance erratic engine operation transmission operation Some vehicles may exhibit the above characteristics as well as transmission hunting Corrosion or spreading of the female terminals in the 3 way throttle position sensor connector could be the problem Diagnosis and repair as necessary White smoke at start up At cold ambient conditions white smoke can be a condition This bulletin applies to trucks built after 1 1 91 The repair involves replacing the air temperature sensor If the engine serial number is higher than 44623028 the sensor is of the new design CATEGORY 19 STEERING TSB MODELS 19 02 05 B 94 95 BR trucks 11 3 95 with a build date prior to 1 1 95 19 01 94 94 BR 4x4 1 28 94 19 04 94 94 BR 6 3 94 19 03 93 89 93 AD 4 16 93 19 02 91 89 91 AD with four 4 22 91 wheel drive CATEGORY 21 SUBJECT DESCRIPTION Clunk or rattle felt in steering wheel column over rough surfaces or while making a turn The repair involves performing an inspection of suspension and steering components to assure proper torque The replacement of the steering column intermediate shaft is described Slow steering return The bulletin applies to 4x4 trucks with a Dana 60 axle
51. the latest calibration No repair required to the turbocharger e Clean the turbocharger e Update PCM flash calibration to the latest calibration and clean the turbocharger e Replace the turbocharger Update PCM flash calibration to the latest calibration and replace the turbocharger EXHAUST TSB MODELS 11 002 07 07 08 DH D1 9 25 07 2500 3500 11 001 08 07 08 DH D1 5 21 08 2500 3500 11 002 08 07 08 DH D1 5 21 08 2500 3500 A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION Inspection and test procedures for the 6 7 liter diesel particulate filter DPF This bulletin applies to vehicle equipped with a Cummins 6 7 liter engines sales code ETF The customer may experience a malfunction indicator lamp MIL illumination warning chime and an overhead electronic vehicle information center EVIC message that states Catalyst Full Service Required Investigation may reveal that the MIL illumination is due to one or more of the following diagnostic trouble codes DTCs P1451 Diesel Particulate Filter System Performance P2463 Diesel Particulate Filter Soot Accumulation P242F Diesel Particulate Filter Restriction Ash Accumulation The balance of the 10 page bulletin describes the inspection test repair or replacement of the DPF based on the severity of the accumulation in the DPF Cleaning the turbocharger on the Cummins 6 7 liter engine This 17 page bulletin describes th
52. the weather strips Creak noise from instrument panel bezel If a creaking noise occurs coming from the instrument panel bezel add felt tape to dash to dampen isolate the components Snapping noise at right side of instrument panel A snapping noise sounds like a small stone hitting the window may occur If diagnosed add a pad to the stiffening rib of the instrument panel to isolate the components Warped tailgate Vehicles built at the Warren truck assembly plant Dodge City complex between 1 10 94 and 2 15 94 are suspect Inspect as tailgate may be twisted or warped on the right side Check the run number for date of production Check the last three digits as 02X through 05X are suspect Replace as necessary Tailgate rattle If a tailgate rattle is heard inspect the tailgate pivot bracket Repair as described in bulletin with replacement stud and bearing mount Popping or snapping noise from windshield The condition is a noise from the base of the windshield while traveling over rough roads irregular surfaces The repair involves removing windshield spacers at the base of the windshield Cowl cracks The condition is cracking or popping sounds from the cowl area at the lower corners of the windshield Inspect the area underneath the fender at the cowl welds The fenders must be removed to see the cracks The repair involves installing cowl reinforcement brackets to the cowl Glue seeps out at backlight or windshield mou
53. vehicles built before April 18 2011 The customer may experience whistle and or high pitch windnoise at door near windshield A pillar This bulletin involves installing a foam stuffer block into door weatherstrip EMISSIONS CONTROL 25 002 10 11 DD DP 9 22 10 Misassembled diesel exhaust fluid engine coolant control valve This bulletin applies to vehicles equipped with the Cummins engine built between March 3 2010 and July 19 2010 Some trucks may have been built with a DEF engine coolant control valve that may be internally misassembled which may not be able to completely shut the flow of coolant passing through the coolant tubes in the DEF tank This allows the DEF temperature to rise above its normal operating range DEF that has been exposed to elevated temperatures can cause the DEF to degrade This bulletin involves replacing the diesel exhaust fluid DEF engine coolant control valve assembly Some of the involved vehicles may also require draining and adding DEF A Publication of the TURBO DIESEL REGISTER TSBs Issued During 2012 CATEGORY 8 ELECTRICAL TSB MODEL 08 011 12 12 DJ DD D2 DP 2 8 102 SUBJECT DESCRIPTION Radio anti theft codes Starting in model year 2012 radios will come equipped with an anti theft feature Once a radio is installed in a vehicle it learns the vehicle s VIN and cannot be used in another vehicle unless an anti theft code is applied This information only TSB tells the dealer
54. with a CPL 2022 or 2023 should be utilized when checking or performing injection pump timing CATEGORY 10 STEERING TSB MODELS SUBJECT DESCRIPTION 19 01 96 95 96 BR Clunk or rattle felt in steering column wheel 2 9 96 The condition is a clunk or rattle in the steering wheel column during slow turns or stops on some 95 96 trucks Diagnosis includes a check of all fasteners for the appropriate torque value 19 05 96 94 96 BR Shimmy after striking a bump or pothole 8 30 96 4x4 trucks with sales This bulletin supersedes TSB 19 04 95 5 12 95 The bulletin discusses a sustaining vibration codes Z8A and Z8B shimmy felt in the front end of the vehicle after striking a bump or pothole The repair procedure and 4x2 cab chassis involves replacing the steering damper replacing the track bar if necessary and the addition of Z3B built before an auxiliary steering damper 5 15 96 _ 8 A Publication of the TURBO DIESEL REGISTER CATEGORY 19 STEERING continued TSB MODELS 21 04 96 96 BR 3 15 96 21 13 96 96 BR 9 20 96 4x4 21 15 96 95 97 BR 11 8 96 CATEGORY 23 SUBJECT DESCRIPTION Transmission will not upshift following a 3 2 downshift Under certain conditions the transmission will not upshift following a 3 2 downshift In this condition the engine will continue to operate at maximum governor speed in second gear until the throttle is reduced The condition only occurs if the over
55. 0 or 2007 D1 3500 05172334AG or higher 2008 DH 2500 or 2008 D1 3500 05172529AG or higher 2009 DH 2500 or 2009 D1 3500 MIL illumination due to P2000 P2A00 and or P2A01 The customer may experience MIL illumination Further investigation by the technician may find one or more of the following DTC s present P2000 NOx Absorber Efficiency Below Threshold Bank 1 P2A00 O2 Sensor 1 1 Circuit Performance P2A01 O2 Sensor 1 2 Circuit Performance This bulletin involves verifying all TSBs related to high sooting issues have been properly addressed replacing both Oxygen O2 Sensors and wrapping the exhaust pipe in the area of the FRONT O2 sensor Engine systems and exhaust aftertreatment systems enhancements This bulletin applies to vehicles equipped with a Cummins 6 7 liter engine sales code ETJ built on or before January 13 2009 This bulletin supersedes technical service bulletin 18 009 07 Rev B dated July 13 2007 This bulletin involves verifying that the latest software has been installed on 2007 MY vehicles Selectively erasing and reprogramming the Engine Control Module ECM Selectively erasing and reprogramming the Cab Compartment Node CCN The latest PCM software will address the erroneous MIL illumination of the following faults P0191 Fuel Rail Pressure Sensor Circuit Performance P0128 Thermostat Rationality P0106 Manifold Absolute Pressure Sensor Performance P0524 Engine Oil Pressure Too Lo
56. 00 6 7L Automatic Transmission 50 State 61301430AK or higher DM 4500 5500 6 7L Manual Transmission 50 State 61301434AK or higher DM 4500 5500 6 7L Automatic Transmission 50 State e If the vehicle in question is a 2009 model year vehicle then compare the current PCM software level part number to one of the following part numbers or with a higher suffix 71300430AH or higher DC 3500 6 7L Manual Transmission 50 State 71300434AH or higher DC 3500 6 7L Automatic Transmission 50 State 71301430AH or higher DM 4500 5500 6 7L Manual Transmission 50 State 71301434AH or higher DM 4500 5500 6 7L Automatic Transmission 50 State e Determine if the current CCN module level software part number is one of the following or with a higher suffix 05172187AH or higher 2007 DC 3500 DM 3500 4500 05172334AG or higher 2008 DC 3500 DM 3500 4500 05172529AG or higher 2009 DC 3500 DM 3500 4500 MIL illumination and stationary DeSoot and other enhancements his bulletin applies to D1 DH vehicles equipped with a 6 7 liter Cummins engine sales code ETJ built before May 5 2009 The customer may experience e An erroneous MIL illumination for P2262 Turbocharger Boost Pressure Not Detected Mechanical e Improved diagnostics for P2299 Brake Pedal Position Accelerator Pedal position Incompatible e An erroneous MIL illumination for P0402 Exhaust Gas Recirculation EGR Flow Excessive Detected e An erroneous MIL
57. 007 model year vehicle then compare the current ECM software level part number to one of the following part numbers or with a higher suffix 55350430AZ or higher DH 2500 6 7L Manual Transmission 50 State 55350435AZ or higher DH 2500 6 7L Automatic Transmission 50 State 55351430AZ or higher D1 3500 6 7L Manual Transmission 50 State 55351435AZ or higher D1 3500 6 7L Automatic Transmission 50 State e If the vehicle in question is a 2008 model year vehicle then compare the current ECM software level part number to one of the following part numbers or with a higher suffix 62350430AR or higher DH 2500 6 7L Manual Transmission 50 State 62350435AR or higher DH 2500 6 7L Automatic Transmission 50 State 62351430AR or higher D1 3500 6 7L Manual Transmission 50 State 62351435AR or higher D1 3500 6 7L Automatic Transmission 50 State e Ifthe vehicle in question is a 2009 model year vehicle then compare the current ECM software level part number to one of the following part numbers or with a higher suffix 72350430AF or higher DH 2500 6 7L Manual Transmission 50 State 72350435AF or higher DH 2500 6 7L Automatic Transmission 50 State 72351430AF or higher D1 3500 6 7L Manual Transmission 50 State 72351435AF or higher D1 3500 6 7L Automatic Transmission 50 State e Determine if the current CCN module level software part number is one of the following or with a higher suffix 05172187AG or higher 2007 DH 250
58. 07 Dodge Ram trucks equipped with the 5 9 Cummins Turbo Diesel engine are allowed by Federal law to be fueled with low sulfur diesel fuel and are encouraged to fuel with ultra low sulfur diesel fuel The new ultra low sulfur highway diesel fuel enables vehicles equipped with the advanced emissions control devices to achieve more stringent U S EPA vehicle emissions standards CATEGORY 14 FUEL continued 14 007 06 06 07 DH D1 DC Rev A 09 02 06 Fuel and fuel filtering requirements for Cummins 5 9 liter and 6 7 liter engines This bulletin supersedes technical service bulletin 14 007 06 dated August 25 2006 This information only bulletin involves a discussion regarding fuel system requirements The bulletin applies to vehicles equipped with a 5 9 liter High Output or a 6 7 liter Cummins Turbo Diesel engine sales codes ETH or ETJ respectively that were built on or after March 07 2006 Bulletin highlights follow For the diesel engine system to operate at its peak performance a high level of fuel quality must be maintained Emission control and fuel delivery systems have advanced significantly Care must be taken to ensure that the fuel that is delivered to the engine fuel injection system is of the highest quality possible and free of contaminants Significant components to fuel quality are the initial quality of the fuel as dispensed from the service station fuel pump or bulk storage on vehicle fuel storage and the on vehicle
59. 18 24 99 11 15 99 CATEGORY 19 00 BR e Inspect the fuel tank rollover valve for restrictions and to ensure that the shipping cap has not been left on the end of the valve Inspect the charge air cooler hoses and clamps for proper installation Inspect all connections and clamps for looseness Verify that no leaks are present when the engine is under boost conditions e While performing the following road test verify that the turbo boost pressure is 16 psi during wide open throttle WOT acceleration e While road testing the vehicle in a safe area and manner conduct an acceleration test For vehicles equipped with an automatic transmission conduct a 0 60 mph acceleration test For vehicles equipped with a manual transmission conduct a 40 60 mph acceleration test in fourth gear It may take the technician performing several acceleration tests to obtain consistent acceleration times A performance vehicle tire size weight chart is provided A summary of the chart reveals 0 60 mph test for automatic trucks 13 5 to 15 secondsis acceptable In the 40 to 60 mph test for manual trucks in fourth gear can vary from 7 5 to 9 0 seconds Correction factors for vehicle weight and altitude are presented 5 9L 24V diesel engine intermittent engine stumble This information applies to vehicles equipped with a 5 9L 24V diesel engine built before engine serial number 56624822 with a date of manufacture of August 28 1999 This information is ava
60. 2005 through December 11 2005 The Antilock Brake System ABS control module on about 37 900 of the above vehicles may cause the rear brakes to lock up during certain braking conditions This could result in a loss of vehicle control and cause a crash without warning Repair The ABS control module must be replaced and initialized with the StarSCAN tool A Publication of the TURBO DIESEL REGISTER CUSTOMER SATISFACTION NOTIFICATION F19 ROLL OVER VALVE VENT HOSES Date June 2006 Models 06 DH Dodge Ram 2500 Pickup and Cab Chassis 06 D1 Dodge Ram 3500 Pickup and Cab Chassis This notification applies only to the above vehicles equipped with a 5 9L diesel engine C in the eighth VIN position built through February 1 2006 The roll over valves on about 69 300 of the vehicles may allow water to enter into the fuel tank Excessive water in the fuel can damage the injection pump and or injectors if the engine is off for an extended period of time Repair A vent hose must be installed at each tank roll over valve ROV The fuel system must be inspected for excessive water content If excessive water is found the water must be removed and the fuel filter must be replaced EMISSIONS RECALL G30 REPLACE OXYGEN SENSOR MODULE AND REPROGRAM ECM Date October 2007 Models 07 08 DH D1 Dodge Ram 2500 3500 Pickup Truck This notification applies only to the above vehicles equipped with a 6 7 liter diesel engine built throu
61. 3 04 DR 03 04 DR 04 DR 04 DR Powertrain control module PCM shift quality improvements The bulletin applies to vehicles equipped with a 5 9L standard output Cummins diesel engine sales code ETC and a 47RE transmission sales code DGP built before December 31 2002 The vehicle operator may find that the vehicle will not shift out of third gear at throttle be tween 50 and 90 until 70 mph The repair involves selectively erasing and reprogramming the powertrain control module PCM with new software No throttle response lack of power while towing and diagnostic trouble codes DTC P2638 P0700 The bulletin applies to vehicles equipped with a Cummins diesel engine sales code ETC or ETH built on or before July 25 2003 The vehicle may exhibit e No throttle response if the engine is started with the Accelerator Pedal Position Sensor APPS in an off idle position pedal depressed and the transmission is shifted into drive or reverse while the APPS remains in an off idle position pedal depressed causing the engine to remain at idle e Lack of power while towing or hauling a heavy load with the transmission in overdrive vehicles equipped with 47RE transmission The repair involves selectively erasing and reprogramming the Cummins CM845 engine control module ECM with new software Generic Cummins engine control module ECM procedure This bulletin applies to Ram trucks equipped with the 5 9L
62. 6587424 The ESN is located on the engine data plate which is located on the front left side of the engine affixed to the gear housing Anoise may be present which on initial investigation may sound like a noisy turbocharger bearing The sound of the noise may be described as a whistle a squeal a howl a moan or a gurgle The noise will be more noticeable as engine temperature increases The noise will most often occur when the warm engine is operated between 1 500 and 2 200 rpm s The noise is usually heard in the cab louder on the passenger side or seems to come form the dash vents The noise may be caused by the coolant supply hose connector The connector is located on the cylinder head next to the turbocharger The connector is used to supply coolant to the heater hose The bulletin describes the replacement of the hose connector VEHICLE PERFORMANCE TSB MODELS 18 02 99 98 99 BR 02 19 99 18 07 99 98 99 BR 04 30 99 SUBJECT DESCRIPTION Erratic torque converter clutch TCC operation This information applies to vehicles equipped with a 5 9L 24 valve diesel engine and automatic transmission built between January 1 1998 and December 18 1998 Some vehicles may exhibit a surge like condition while in fourth gear This may be caused by the TTC unlocking and locking when it should be consistently locked The cause of this erratic operation has been identified as electrical noise from the Throttle Position Sensor
63. 7 03 14 07 62 98 5 02 BR 03 05 DR 06 06 07 DR DH D1 07 DC 05 06 DH D1 06 DH D1 03 05 DR Cummins engine control module ECM procedure Mopar is phasing out pre programmed Cummins diesel engine control modules ECM New modules will no longer be pre programmed when received from Mopar Replacement of future ECM s will require programming at the dealership This bulletin describes the programming procedure Flash engine performance white smoke This bulletin applies to Ram trucks equipped with the 5 9L Cummins 24 valve diesel engine sales code ETH built on or after June 9 2005 through and including November 8 2005 This bulletin involves programming the PCM Cummins with new software The software is designed to reduce white smoke and improve engine performance after a cold start at ambient temperatures below 60 F and to improve oil pressure gauge operation StarSCAN StarMOBILE abort recovery procedures This information only bulletin supersedes technical service bulletin 18 001 06 dated January 11 2006 and provides guidelines to minimize flash reprogramming problems and recovery procedure information for failed flash attempts Flash long crank when starting and or transmission shift and battery charging enhancements This bulletin applies to Ram trucks equipped with the 5 9L Cummins 24 valve diesel engine sales code ETH built on or after January
64. 97 BR 10 11 96 08 47 96 97 BR 12 20 96 A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION Cassette auto load error on RAS code radio This information only bulletin describes a condition where the radio may enter the cassette play mode without a cassette being inserted The bulletin explains the correction and discusses the function of the Ignition Off Draw IOD fuse Wiring harness connector repair packages This information only bulletin helps the service technician by providing a part number listing for the correct electrical components per an assembly It also gives a review of the diagnosis procedure for electrical components Clicking noise from speedometer If a clicking ticking noise is heard coming from the instrument cluster area the bulletin describes the repair procedure to replace the speedometer Trailer tow wiring information Chrysler Corporation has offered optional trailer tow packages on all 94 through 97 Dodge Ram Trucks and has made trailer tow packages available through Mopar for vehicles that were not built with the trailer tow package Several changes to the trailer tow wiring have occurred since the truck was introduced It also identifies flashers This bulletin identifies the part numbers for the Mopar trailer tow packages required to adapt trailer wiring to a vehicle that did not have the trailer tow package installed as original equipment from the factory Radio interference f
65. Better anti wear properties e Improved rust corrosion prevention e Controls oxidation e Eliminates deposits e Controls friction e Retains anti foaming properties e Superior properties for low temperature operation Mopar ATF 4 is a World Class Fluid having exceptional durability However the red dye used in ATF 4 is not permanent as the fluid ages it may become darker or appear brown in color ATF 4 also has a unique odor that may change with age With ATF 4 fluid color and odor are no longer indicators of fluid condition and do not support a fluid change WHEELS TSB MODELS 22 001 01 00 01 BR BE Rev A 9 28 01 48 SUBJECT DESCRIPTION Chrome wheel care Chrome wheels should be cleaned regularly with mild soap and water to maintain their luster and prevent corrosion Wash them with the same soap solution as the body of the vehicle To clean extremely dirty wheels care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels Only Mopar Wheel Treatment p n 05066247AB 12 oz Or 05066248AB 5 gal is recommended to remove brake dust dirt grease and grime Any of the DO NOT USE items listed below can damage or stain wheels and wheel trim DO NOT USE e Any abrasive type cleaner e Any abrasive cleaning pad such as steel wool or abrasive brush Any cleaner that contains an acid this will immediately react with and discolor the chromium surface
66. C s and Erroneous LDP Switch This bulletin applies to vehicles with an RE automatic transmission built before January 12 2001 MDH 0112XX A generic scan tool may not display certain Diagnostic Trouble Codes DTC when a Malfunction Indicator Lamp MIL illuminates The PCM software must be updated to calibration level OlCall4A Scan Tool Erroneously Displays POOO For DTC s P1740 And P0461 This bulletin applies to vehicles with an RE automatic transmission built before January 31 2001 MDH 0131XX A Generic Scan Tool or an Enhanced Scan Tool like the DRB Ill may erroneously display certain Diagnostic Trouble Codes DTC as P0000 As a result the scan tool may display Freeze Frame data incorrectly The PCM software must be updated to calibration level OlCall4A 5 CATEGORY 2 TSBs Issued 2003 2009 FRONT SUSPENSION TSB 02 003 02 6 17 02 02 003 08 6 20 08 MODELS 00 02 BR BE 08 DM 4500 5500 CATEGORY 3 SUBJECT DESCRIPTION Toe in specification change This bulletin involves an update to the toe in specification for front end alignments The specification for toe in has been revised to 0 2 0 1 total toe in This change has been shown to improve straight ahead driving performance and should be used whenever a front end alignment is performed Front and or rear shock absorber noise The customer may experience a clunking like sound when traveling over small inputs bumps and dips in th
67. C C 1240 This bulletin involves the diagnosis and possible replacement of the steering angle sensor This bulletin applies to vehicles equipped with the Electronic Stability Program sales code BNB and built prior to October 03 2006 The customer may experience an illumination on the instrument cluster of the ABS anti Lock Brake System and or the ESP BAS Electronic Stability Program Brake Assist System warning lights Investigation may reveal the presence of diagnostic trouble code DTC C1240 Steering Angle Sensor Over Travel Performance If the diagnostic test procedure for DTC C1240 determines that the steering angle sensor is at fault then perform the repair procedure Cell phone induced buzz or clicking like sound in radio speakers This bulletin involves a discussion regarding cell phone generated signal interference with the vehicle radio system A customer may experience a buzzing or clicking like sound coming from the vehicle radio speaker s The sound may be heard when the radio is in AM or FM mode The clicking like sound may sound like Morse code This information only bulletin points out that the construction of certain cell phones may generate frequencies that can interfere with the vehicle radio system These frequencies may result in buzzing and or clicking like sounds in the vehicle radio This condition can be easily corrected by instructing the customer to move their cell phone away from the immediate area around vehi
68. Cummins 24 valve diesel engine sales code ETC or ETH Mopar is phasing out pre programmed Cummins Diesel engine control modules ECM New modules will no longer be pre programmed when received from Mopar Replacement of future ECM s will require programming utilizing the DRBIII and Tech CONNECT Poor A C performance slow fuel gauge response and diagnostic trouble codes PO341 and P1757 This bulletin applies to vehicles equipped with a Cummins Turbo Diesel engine sales code ETC or ETH with an engine serial number 57130284 or earlier and the engine date of manufacture on or before December 10 2003 The owner of the vehicle may describe slow fuel gauge response after adding fuel On California emission equipped vehicles the problem is rapid A C clutch cycling and poor A C performance until coolant temperature reaches 170 The repair involves erasing and reprogramming the Cummins ECM with new software Poor cab heat and or slow engine warm up in cold ambient temperatures This bulletin applies to DR vehicles equipped with a Cummins Turbo Diesel engine sales code ETC or ETH and an automatic transmission with an engine serial number 57130284 or earlier and the engine date of manufacture on or before December 10 2003 The vehicle operator may describe poor cab heat and or slow engine warm up in cold ambient temperatures A new feature has been added that allows the vehicle operator to use the speed control switches to increase the engine spee
69. E PEFORMANCE continued TSB MODEL SUBJECT DESCRIPTION 18 029 11 11 DD DP Engine systems and PTO enhancements 5 28 11 This bulletin applies to vehicles equipped with a Cummins engine built before January 1 2011 These cab chassis trucks have a number of software improvements available This latest service bulletin will include Improvements to prevent unnecessary malfunction indicator lamp MIL illumination for P0524 fault for low oil pressure set during low ambient temperatures P051B fault for crankcase pressure Enhanced diagnostics for e Variable geometry turbocharger e Fuel level sensor Other updates e Low diesel exhaust fluid DEF level EVIC messaging strategy changes e Diesel exhaust fluid DEF system tampering EVIC messaging strategy changes e Oil change monitor updated for easier reset same basic procedure easier to reset e Scan tool display updates e Enable mobile PTO capability e Correct operation of remote PTO e Correct EVIC messaging related to DEF level reporting e System robustness improvements DEF tank level reporting erroneously at high DEF tank level When DEF tank is overfilled the EVIC may display low fluid level 20 22 This bulletin involves selectively erasing and reprogramming the engine control module ECM with new software CATEGORY 19 STEERING 19 001 11 08 10 DM Tie rod ball stud housing alignment procedure Rev A 11 DP This bulletin describes the proper proced
70. ELS 09 002 01 98 01 BR 03 02 01 09 001 01 01 1 19 01 09 003 01 All 5 4 01 09 004 01 89 93 AD 5 18 01 94 01 BR BE 09 006 01 98 02 BR 08 24 01 09 002 02 98 02 BR 3 11 02 A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION Exhaust manifold bolt retention straps This bulletin applies to vehicles equipped with a 24 valve diesel engine built on or between engine serial number 56419738 and 56777585 with a date of engine manufacture from January 01 1998 to September 22 2000 This information is available on the engine data plate which is located on the left side of the engine affixed to the side of the timing gear housing Intermittent loss of oil pressure sensor ouput voltage This bulletin applies to 2500 3500 diesels with engine serial number 56744083 to 56809910 The output voltage of the oil pressure sensor may intermittently dropout This condition may cause the engine oil pressure gauge needle to erroneously indicate lower than actual oil pressure A warning chime may sound and the Check Gauges lamp may illuminate The Engine Control Module ECM software has been revised to address this condition Replacing the oil pressure sensor will not correct this condition Engine oil additives supplements Engine oil additives supplements EOS should not be used to enhance engine oil performance Engine oil additives supplements should not be used to extend engine
71. FRAME amp BUMPERS TSB MODELS 13 001 03 03 DR 2 7 03 CATEGORY 14 SUBJECT DESCRIPTION Frame alterations This bulletin is to support the 2003 Body Builder s Guide and presents guidelines that must be followed during modifications or alterations to any 2003 Dodge Ram pickup frame The following general industry standard procedures are recommended for proper installation of special bodies and or equipment on the Ram pickup frame such as fifth wheel hitches snow plows etc Failure to follow these recommendations could result in damage to the basic vehicle and possible injury to occupants The information only bulletin gives the guidelines for welding and drilling of holes into the frame FUEL TSB MODELS 23 018 02 00 01 BR BE 5 20 02 SUBJECT DESCRIPTION Fuel cap difficult to remove This bulletin involves installing a revised fuel cap A Publication of the TURBO DIESEL REGISTER CATEGORY 14 FUEL continued 14 002 02 98 02 BE BR Rev A 6 13 03 14 005 02 03 DR 11 8 02 14 004 05 03 05 DR 14 003 06 03 07 Rev A DR DH D1 DC 10 27 06 14 005 06 07 DH D1 DC 07 27 06 A Publication of the TURBO DIESEL REGISTER Tampering with VP44 fuel pump on Cummins diesel engine This bulletin supersedes technical service bulletin 14 002 02 dated July 1 2002 A number of the VP44 fuel pumps have been returned through the warranty process as a result of tampering
72. LS 94 99 BR 98 99 BR 94 00 BR 98 99 BR 94 00 BR SUBJECT DESCRIPTION Instrument panel creak This bulletin supersedes technical service bulletin 23 45 96 dated August 2 1996 A creak or squeak may be present near the left and or right side s of the instrument panel The noise is caused by the sheet metal joint between the A pillar and the dash panel plenum lower rubbing together This bulletin describes the repair procedure which involves loosening the instrument panel and providing additional clearance between the A pillar inner panel and dash panel Bezel comes loose from seat belt retractor cover This bulletin applies to club quad cab vehicles The seat belt retractor cover bezel comes loose due to a cracked seat belt retractor cover The crack may occur at the bottom of the opening where the seat belt bezel snaps into the cover This bulletin describes the installation of a new seat belt retractor cover Rattle in door area This bulletin supersedes technical service bulletin 23 46 96 dated August 2 1996 Customers may complain of one or more of the following symptoms rattle heard in the door area door window shakes when closing door lower window channel bolt has pulled through the door sheet metal door sheet metal is cracking around the lower window channel bolt This bulletin involves removing the window channel from the door and installing a revised window channel Power se
73. ODELS 00 01 BR BE 03 DR 03 DR 03 DR 03 DR SUBJECT DESCRIPTION Armrest lid difficult to open The armrest lid may be difficult to latch or if latched may be difficult to open This may be caused by an improperly adjusted latch pin This bulletin involves adjusting the armrest lid latch pin Instrument panel whistle Awhistling sound may be present coming from the front of the instrument panel near the bottom of the windshield when the heater A C blower is on This may be caused by air escaping through the holes in the center of the rivets that attach the VIN plate to the instrument panel This can be mis diagnosed as a windshield air leak If necessary remove the instrument panel top cover and apply a small drop of clear glass sealer to the center of each of the rivets to seal the rivet holes Buzzing or vibrating sound coming from the front of the vehicle The description of the problem is a buzzing or vibrating sound coming from the front of the vehicle at highway speeds Open the hood and inspect the ID plate located on the radiator support The ID plate should be attached with four rivets If there are only two rivets securing the ID plate the ID plate may be vibrating against the radiator support The repair involves securing the ID plate with additional rivets Scratched aftermarket window tint film Customers who have installed aftermarket window tint film see scratches on the film on the windo
74. OTICES OUTER DASH SILENCER PAD AND HEAT SHIELD SAFETY RECALL 737 The outer dash silencer pad on the below listed vehicles may contact the exhaust pipe Under certain operating conditions the exhaust pipe may become not enough to over heat or ignite the silencer pad To correct this condition part of the silencer pad must be removed and a heat shield must be added to the exhaust pipe Models 1997 model year Dodge Ram BR trucks equipped with a 5 9L diesel engine D in the 8 VIN Position built at the Saltillo Assembly Plant G in the 11 VIN Position from March 7 1997 through May 15 1997 St Louis North Assembly Plant J in the 11 VIN Position from March 15 1997 through May 16 1997 Lago Alberto Assembly Plant M in the 11 VIN Position from March 18 1997 through May 15 1997 The service repair procedure involves removal of a portion of the silencer pad and the installation of heat resistant foil tape to the remainder of the silencer pad and the installation of a heat shield onto the exhaust pipe IGNITION SWITCH WIRING RECALL 875 The ignition switch and or steering column wiring may overheat when the blower motor is operated at high speed for an extended period of time This can cause stalling loss of blower motor or power window operation ABS or airbag lamp illumination or a steering column instrument panel fire The vehicles involved in the recall have a vehicle identification
75. PM current trigger point for DTC P1277 from 75 amps to 100 amps If any of the DTC s listed above are present perform the repair procedure A Publication of the TURBO DIESEL REGISTER ELECTRICAL continued CATEGORY 8 08 026 06 06 DR DH D1 Rev A 10 25 06 08 044 06 07 DR 10 07 06 08 046 06 04 07 10 25 06 08 003 07 07 DR DH D1 DC 01 27 07 08 015 07 06 07 DR 06 06 07 08 018 07 07 DR DH D1 DC 06 23 07 A Publication of the TURBO DIESEL REGISTER Overhead console temperature reading inaccurate or dome lamp turns off too soon This bulletin supersedes technical service bulletin 08 026 06 dated June 02 2006 This bulletin involves selectively erasing and reprogramming the cabin compartment node CCN with new software This bulletin applies to vehicles built on or before May 30 2006 The vehicle owner may notice that if a vehicle door is left open for longer than 20 seconds the illuminated interior dome lamps will turn off Or the vehicle operator may report that the ambient temperature first displayed in the overhead console is not accurate displays 40 C or 40 F when the ignition switch is turned to the On position then slowly updates to the outside ambient temperature as the vehicle is driven If the vehicle operator describes or experiences the symptom condition perform the repair procedure which involves a reflash to the CCN Steering angle sensor over travel performance DT
76. The bulletin supersedes TSB 02 01 96 dated 3 15 96 The bulletin applies to body style codes 31 32 and 62 with one of the listed GVW sales codes Z2B Z3A Z7B Z8A or Z8B The bulletin describes the parts and installation procedure for a special service kit developed for use by owners that consistently carry a box mounted camper A rear stabilizer bar and auxiliary spring comprise the kit Creaking noise from rear of vehicle The diagnosis involves the inspection of the rear leaf spring assembly to verify the appropriate number of spring tip inserts are present If tip inserts are broken or missing the repair procedure is detailed in the TSB Lower ball joint replacement This bulletin applies only to two wheel drive vehicles It discusses the service differences in tack welded ball joints control arms and non tack welded ball joints control arms Track bar ball joint diagnosis The bulletin refers to the 97 Truck Service Manual and is a supplement to help the technician troubleshoot loose or worn steering components The track bar ball joint previously did not have an inspection procedure REAR AXLE TSB MODELS 03 02 96 94 96 BR 5 10 96 2500 and 3500 4x2 trucks regular cab automatic transmission and two piece propeller shafts 03 03 96 94 96 BR 8 16 96 With automatic transmission and 5 9 Turbo Diesel engine Note 96 2500 club cab 155 WB 4x4 with heavy duty transfer case built after 5 9 96 have t
77. This bulletin applies to vehicles equipped with an AM FM cassette radio built prior to January 30 2004 or AM FM CD radio built prior to January 30 2004 Radios built after 1 30 04 will no longer have vent holes in the area the repair procedure covers If the audio drops out when the vehicle is moved from a cold to a warm or humid environment the reason is that condensation builds up across the audio amplifier circuitry causing the amplifier to shut down Typically cycling the ignition switch off and on will restore the audio output If the problem persists the correct repair procedure is to apply tape over the row of slots on the left hand side of the radio s top cover Mopar accessory remote starter inoperative due to hood switch This bulletin applies to vehicles equipped with a Mopar remote starter kit The problem frequently occurs as one or more of the following e When the transmitter is pressed twice for start the vehicle horn will chirp once but the vehicle engine will not start e When the transmitter is pressed twice for start the vehicle horn will chirp twice indicating a problem with the remote start system and the vehicle engine will not start e When the transmitter is pressed twice for start the vehicle will chirp once the engine will start and then turn off The technician may not be able to verify the symptom s because it may be an intermittent condition The corrective action involves replacing the hood switch for the remote
78. a 5 9L 24V diesel engine built between engine 12 21 00 serial numbers 56419738 to 56798357 with a date of manufacture of December 16 1997 to November 15 2000 The customer may complain of poor driveability when winter fuel is used to power the engine Or the customer may complain of a hard or no start condition while the engine is at normal operating temperatures when using any type of good quality diesel fuel The poor driveability condition may occur only when either straight 1 diesel fuel is used or when other special cold climate winter blend fuels are in use The no start or long engine crank condition may occur when attempting to restart the engine while the temperature of the engine is till close to its normal operating temperature This hard hot restart condition may be experienced in all ambient climates but may be more of a concern in warmer ambient climates The repair involves selectively erasing and reprogramming the Cummins CM551 Engine Control Module ECM with new software 18 024 00 01 BR Low engine power when the automatic transmission is in overdrive 12 21 00 This bulletin applies to vehicles equipped with a 24 valve diesel engine and automatic transmission built between engine serial numbers 56666444 to 56798357 with a date of manufacture of December 15 1999 to November 15 2000 This information is available on the engine data plate which is located on the left side of the engine affixed to the side of the timin
79. ably higher than the actual fluid level Filling the axle until the fluid comes out of the fill hole will overfill the axle which could cause fluid foaming When checking fluid level or filling a rear axle with fluid you must measure distance from the bottom of the fill hole to the actual fluid level This can easily be accomplished using a pipe cleaner or piece of wire Make a 90 degree bend in the wire two inches from the end The wire can then be inserted into the axle fill hole and used as a dipstick Measure the distance from the bend to the oil level The fluid levels for the axles are shown in the table below Ram Truck 2500 3500 Axle Fluid Level measured from the bottom of the fill hole Fluid Capacity 10 5 Rear Axle 1 inch inch 85 oz SAE 75W 90 Synthetic 11 5 Rear Axle inch inch 122 oz SAE 75W 90 Synthetic 9 4 Front Axle Y inch inch 76 oz SAE 75W 90 Synthetic Note The limited slip feature on 2500 3500 series Ram Trucks utilizes the Trac Rite locking feature which does not require Trac Lok additives or friction modifiers CATEGORY 6 CLUTCH TSB MODELS SUBJECT DESCRIPTION 06 001 03 03 BR Rattle sound from transmission when idling 5 16 03 This bulletin applies to vehicles equipped with a 5 9L Cummins high output Turbo Diesel sales code ETH and NV5600 six speed manual transmission sales code DEE built on or before May 11 2003 The vehicle operator may describe a rattle sound when idling in neutral with the cl
80. actory installed options e g snow plow tires or wheels of different size aftermarket wheels tires that have a belt that has shifted incorrect tire pressure a vehicle that is carrying extra added weight e g tool boxes steering and or suspension components that are worn or damaged wheel bearings that are worn or damaged a vehicle that is not with in alignment specifications brake drag from brake components that do not release or braking imbalance Additionally under certain road conditions e g high road crown grooved roads etc most vehicles will move to the right or left uncontrolled by the driver Also the same may happen if a cross wind condition exists Revised power brake booster check valve This bulletin applies to vehicles equipped with the 5 9L Cummins diesel engine A revised power brake booster check valve p n 05011393AA has been released for service The new check valve performance has been improved by changing the flapper style check valve to a spring loaded style check valve The spring loaded style check valve performance is superior especially in vehicles that utilize mechanical vacuum pumps to provide the vacuum source to operate the power brake booster Part number 05011393AA should be used any time the power brake booster check valve is serviced on the subject model vehicles A Publication of the TURBO DIESEL REGISTER CATEGORY 8 ELECTRICAL TSB MODELS 08 06 99 98 00 BR Rev A 12 17 99
81. ady for testing Non Methane Hydrocarbon NMHC Catalyst Monitor b Nitrogen Oxide NOx Absorber Monitor c Exhaust Gas Temperature Sensor Monitor d Electrical Charging System Monitor e f EGR System Monitor Oxygen Sensor Monitor e After extensive idling of the vehicle engine or if an intake air leak is present the vehicle operator may experience a MIL illumination and or an electronic vehicle information center EVIC message alert due to one or more of the following DTCs P1451 Diesel Particulate Filter System performance P2463 Diesel Particulate Filter Soot Accumulation P242F Diesel Particulate Filter Restriction Ash Accumulation The vehicle operator may experience a MIL illumination due to one of the following DTC s P0106 Manifold Absolute Pressure Sensor Performance P242B Exhaust Gas Temperature Sensor Circuit Performance Bank 1 Sensor 3 P245A EGR Cooler Bypass Control Circuit Open e An intermittent rough engine idle and or white smoke following initial engine start e Athrottle tip in stumble at engine speeds of 1 300 to 2 100 rpm e An engine hesitation at altitude of 5 000 feet between engine speeds of 1 200 to 1 600 rpm A turbocharger chuff like sound during rapid deceleration This bulletin involves selectively erasing and reprogramming the Powertrain Control Module PCM with bootloader software and application software A Publication of th
82. air The vehicle must be inspected for the type of steering linkage the vehicle is equipped with and those found with a certain linkage configuration must have the right and left tie rod angles measured If the tie rod angles are not within specification the left tie rod must be replaced Note special Tool 10326 was released to dealers in November of 2010 Service Bulletin 19 001 11 was also issued to alert dealers to the new service tool and procedure for setting toe on the affected and all subsequent vehicles If l ve heard it once I ve heard it a hundred times the TDR reads like a storybook and you have to keep the back issues handy or you ll miss a topic that has been previously covered At times know it is frustrating But for the sake of the editor s sanity and page count containment often do the chapter and verse thing The point of this rambling if you have a problem with a late model truck you ll want to review the TSBs in issues 74 70 66 and 62 all of which can be found at our web site Likewise review those magazines for any recall notices that may apply to you Is the grass greener on the other side We hope the TSB and Recall information will help you in your purchase ownership of the Dodge Cummins Turbo Diesel truck We choose to think that answers and solutions are much better than wonderment Happy Motoring Finally did you notice that the TSBs are fewer in number at the end of a vehicle s life
83. all an overrunning clutch pulley on the generator A Publication of the TURBO DIESEL REGISTER CATEGORY 9 ENGINE continued 09 002 09 07 09 DH D1 Rev A 06 13 09 CATEGORY 11 MIL illumination due to DTC P2262 Revised diagnosis and repair procedures This bulletin applies to vehicle equipped with a Cummins 6 7 liter engine sales code ETJ The bulletin supersedes technical service bulletin 09 002 09 dated 5 2 09 This bulletin discusses revised diagnostic and repair procedures for DTC P2262 Turbocharger Boost Pressure Not Detected Mechanical Recent PCM calibration updates have improved the robustness to this DTC through updated diagnostic strategies As a result many events which have no adverse affects on drivability emissions or reliability will no longer set the P2262 fault As a result of recent PCM calibration updates the proper repair for some P2262 faults is merely to update the calibration while others will require cleaning or replacing the turbocharger Scan Tool software includes a P2262 diagnosis test for this purpose The new P2262 diagnosis test must be used prior to performing any of the following e Clearing codes e Updating the PCM e Beginning the turbocharger repair Based on the outcome of the P2262 diagnosis test the Scan Tool will provide one of the following as the proper direction for the appropriate repair Service info and complete the repair as directed e Update PCM flash calibration to
84. aming properties e Superior properties for low temperature operation Mopar ATF 4 has exceptional durability However the red dye used in ATF 4 is not permanent as the fluid ages it may become darker or appear brown in color ATF 4 also has a unique odor that may change with age With ATF 4 fluid color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change Automatic transmission diagnostic tear down procedure This bulletin provides a procedure to determine repair versus replacement of an automatic transmission assembly Follow the proper repair procedure based on the transmission type This procedure is to be used after the transmission has been removed from the vehicle This bulletin supersedes technical service bulletin 21 008 06 dated 04 08 06 This bulletin supersedes technical service bulletin 21 021 08 dated 09 17 08 Flash New 48RE feature that allows normal shift schedule with full disable of 4th gear overdrive This bulletin applies to vehicles equipped with a 5 9 liter Cummins Turbo Diesel engine and a 48RE automatic transmission sales codes ETH and DG8 respectively Anew 48RE transmission feature is added that will allow normal shift schedule with full disable of 4th gear overdrive gear when the customer selects the Over Drive O D switch Prior to the implementation of this new transmission feature the use of the O D switch changed the automatic transmission shift schedule from
85. and revised caster specifications to improve road feel and correct a vehicle wander condition If the vehicle operator describes the symptom condition perform the repair procedure Steering Wander While traveling on a straight stretch of highway a customer may feel the need to provide steering input to correct a vehicle wander condition This bulletin applies to 4x4 vehicles built before February 4 2009 This bulletin involves installing an Intermediate steering shaft kit part number 05165725AA CATEGORY 21 TSB MODEL 21 003 10 07 DC 5 12 10 CATEGORY 23 TRANSMISSION SUBJECT DESCRIPTION MIL illumination due to transmission related DTC P0711 or P0776 This bulletin applies to 2007 3500 Chassis Cab models equipped with a 6 7 liter diesel engine and an AS68RC automatic transmission This bulletin supersedes service bulletin 21 019 08 dated August 2 2008 The customer may experience a malfunction indicator lamp MIL due to one or both of the following diagnostic trouble codes P0711 Transmission Temperature Sensor 1 Performance P0776 Pressure Control Solenoid B Performance This bulletin involves verifying software levels in the transmission control module TCM and the engine control module ECM Then as necessary selectively erasing and reprogramming the TCM and possibly the ECM BODY TSB MODEL 23 006 10 10 D2 3 10 10 10 DJ 09 DS SUBJECT DESCRIPTION Hood creaking and squeaking
86. at track vertical adjustment stuck in a full upward or full downward position This bulletin applies to club or quad cab vehicles built before March 1 1999 The repair condition is that the front and or rear power seat track vertical adjuster motors are stuck in a full upward or full downward position The repair involves removing existing lubrication on the power seat track adjustment lead screws and then applying a new lubricant Child seat tether anchors This bulletin supersedes technical service bulletin 23 35 99 dated September 3 1999 This bulletin identifies the parts and labor operation numbers necessary to install a child seat tether anchor TSBs Issued During 2000 CATEGORY 2 FRONT SUSPENSION TSB MODELS SUBJECT DESCRIPTION 02 04 00 94 01 BR Squeaking clicking noise from rear leaf springs Rev A If the vehicle has a squeaking clicking noise coming from the rear of the vehicle verify that 05 12 00 the noise is coming from the rear springs as the vehicle s suspension goes through jounce and rebound If a squeaking clicking noise is coming from the rear springs perform the repair procedure The procedure involves replacing the spring tip liners and installing spring clinch clip insolators CATEGORY 5 BRAKES TSB MODELS SUBJECT DESCRIPTION 05 04 00 00 BR High pitched squeal from rear brakes 05 01 00 This bulletin applies to 2500 3500 series Ram trucks built before March 1 2000 The condition
87. available Follow the service procedures in the appropriate service manual to complete necessary repairs Follow normal warranty procedures to report the repairs Automatic transmission fluid usage ATF 4 Type 9602 CATEGORY 21 TRANSMISSION continued 21 006 01 94 02 BR BE 6 29 01 CATEGORY 22 This information only bulletin supersedes technical service bulletin 21 16 99 dated October 22 1999 The bulletin discusses a new transmission fluid ATF 4 Type 9602 which has been developed and is being used as factory fill for all vehicles with Chrysler automatic transmissions Until now vehicles originally filled with ATF 2 or ATF 3 were to be serviced with ATF 3 Effective immediately it is recommended that all vehicles with Chrysler automatic transmissions except for 1999 and earlier minivans be serviced with ATF 4 ATF 3 should continue to be used for 1999 and earlier minivans because of the potential for torque converter shudder during break in For all other applications the ATF 4 fluid offers significant benefits as outlined below ATF 4 must always be used in vehicles that were originally filled with ATF 4 Service intervals do not change The service interval currently in effect for a given vehicle should continue to be followed ATF 4 is compatible with ATF 3 and can be used to top off vehicles that currently have ATF 2 or ATF 3 Do not use ATF 2 or ATF 3 to top off vehicles that have ATF 4 fluid Benefits
88. avy loads These pulses may cause the engine mounted transmission cooler to crack and leak fluid which could result in significant transmission damage Repair The transmission cooler line must be replaced on all involved vehicles In addition the engine mounted transmission cooler must be inspected and replaced if necessary CUSTOMER SATISFACTION NOTIFICATION NO C42 POWERTRAIN CONTROL MODULE CONNECTORS Date February 2004 Models 03 DR This notification applies only to trucks equipped with a 5 9 liter Cummins diesel engine sales code ETC or ETH and an automatic transmission sales code DGP or DG8 built through July 9 2003 The Powertrain Control Module PCM electrical connectors on about 70 000 of the above trucks may allow water to enter into the connectors Water and the resulting corrosion ina PCM connector can cause the speed control and or transmission overdrive function to become inoperative Repair The three electrical connectors on the PCM must be removed and inspected for corrosion If no corrosion is found the connectors must be sealed by installing rubber O rings onto the harness connectors If corrosion is found in the connector the transmission wiring harness and PCM must be replaced A Publication of the TURBO DIESEL REGISTER CUSTOMER SATISFACTION NOTIFICATION E10 FRONT SUSPENSION COIL SPRINGS Date July 2005 Models 05 DH Dodge Ram 3500 4x2 Pickup Truck This notification applies only to th
89. ay effect replacement powertrain control module PCM programming The sixth character in the VIN is used to identify the vehicle series 1500 2500 3500 Some 2003 vehicles equipped with dual rear wheels built prior to July 15 2003 may have an incorrect number as the sixth character of the VIN All vehicles equipped with dual wheels sales code WLA should have the number 4 as the sixth character This identifies the vehicle as a 3500 series equipped with dual rear wheels The incorrectly built vehicles will have the number 3 in that position In the event that a Powertrain Control Module PCM would require replacement the new module requires that the complete VIN be input during the programming procedure If a new PCM is programmed with a 3 as the sixth character and it is equipped with dual rear wheels a conflict is likely to occur with the ABS module which will set an error code Dual rear wheel equipped vehicles require an ABS module calibrated for dual rear wheels If PCM replace ment is ever required simply input a 4 instead of the 3 as the sixth character in the VIN when programming the PCM A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE continued 18 015 03 4 4 03 18 027 03 7 4 03 18 030 03 8 29 03 18 003 04 2 3 04 18 004 04 2 3 04 18 007 04 2 24 04 A Publication of the TURBO DIESEL REGISTER 03 DR 03 DR 98 5 02 BE BR 0
90. band Awasher is installed to prevent contact Speedometer drive gear replacement procedure An information only brochure to supplement the service manual 11 CATEGORY 22 WHEELS amp TIRES TSB MODELS 22 03 95 95 BR 3 3 95 22 04 95 94 95 BR 4 7 95 22 05 95 A 94 95 BR with 6 30 95 code WDC wheels 22 06 95 95 BR 6 16 95 22 03 94 94 BR 6 24 94 22 05 93 93 AD 7 16 93 22 02 92 89 92 AD 4 6 92 SUBJECT DESCRIPTION Match mounted tire wheel combinations The bulletin is an information only bulletin describing a match mounting process to improve ride characteristics Spare tire winch operation The bulletin is an information only bulletin reminding not to use power tools to drive the spare tire winch Wheel runout measurement code WDC wheels procedures The bulletin gives the allowable remount and informs the dealer that the tire must be dismounted to correctly measure radial and lateral runout Match mounting during wheel service The information only bulletin helps dealers match mount wheels and tires Premature rust on chrome wheels Wheels manufactured after 1 1 94 have an improved chrome plating process Wheels prior to 1 1 94 may show signs of premature rust Replacement of the wheels is described Tire and wheel runout A quick reference chart is provided for dealer diagnosing Wheel vibration on 350 Series trucks with flange type lug nu
91. ble Codes DTC when a Malfunction Indicator Lamp MIL illuminates The PCM software must be updated to calibration level OlCall4A Scan Tool Erroneously Displays POOO For DTC s P1740 And P0461 This bulletin applies to vehicles with an RE automatic transmission built before January 31 2001 MDH 0131XX A Generic Scan Tool or an Enhanced Scan Tool like the DRB III may erroneously display certain Diagnostic Trouble Codes DTC as P0000 As a result the scan tool may display Freeze Frame data incorrectly The PCM software must be updated to calibration level OICall4A CATEGORY 2 TSBs Issued During 2002 FRONT SUSPENSION TSB MODELS 02 001 01 94 01 1 19 01 CATEGORY 5 SUBJECT DESCRIPTION Rear of vehicle sits too high to allow hook up to a fifth wheel trailer This bulletin applies to 2500 and 3500 4x4s The curb height lowering package is designed to reduce the rear spring spacer block by 1 7 8 inch which will lower the rear of the vehicle by several inches providing clearance so that most customers can attach their fifth wheel or goose neck trailer to the trailer hitch turntable BRAKES TSB MODELS 05 002 01 01 3 9 01 CATEGORY 8 SUBJECT DESCRIPTION Parking brake pedal adjustment This bulletin applies to 2500 3500 series Ram trucks with four wheel disc brakes built before November 20 2000 Parking brake cable appears to be mis adjusted which may cause the parking brake lamp to remain il
92. cedure 04 14 00 This bulletin applies to vehicles equipped with a 5 9L 24V diesel engine built before engine serial number 56686747 with a date of manufacture of February 09 2000 Analysis of returned fuel filter housing covers has determined that a number of plastic covers are being replaced due to cracks Further analysis has revealed that the cracks may be caused by improper cover removal procedures Do not use the square opening to remove or install the cover The fuel filter cover may crack To remove or install the fuel filter cover correctly only use the 1 1 8 hex head Use of a six point socket is preferred 14 03 00 98 01 BR Maintenance to the Water In Fuel sensor probes due to possible fuel contamination 04 14 00 The probes on the end of the Water In Fuel WIF sensor may become less effective at sensing the presence of water in the fuel if they are exposed to contaminated fuel Contaminant from the fuel may insulate the WIF sensor probes and inhibit the WIF lamp from illuminating when water is present Any time service is performed on the fuel filter or fuel filter housing the probes on the end of the Water In Fuel sensor should be cleaned Use a clean cloth to wipe the WIF probes of any contaminant CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS SUBJECT DESCRIPTION 18 015 00 98 01 BR Driveability enhancements for winter fuel use and for hard starts Rev A This bulletin applies to vehicles equipped with
93. cember 17 1997 equipped with the 24 valve 5 9L Cummins diesel engine Extended idle operation especially in cold weather can allow varnishes oils to condense on the exhaust valve stems leading to stuck valves and damaged valve train components The repair procedure involves calibration software that will activate when certain parameters are met reducing the chance of valve sticking as well as improving cab heat warm up time Idle speed will slowly ramp up from 800 rpm to 1200 rpm when all of the following conditions are met e Intake Manifold Temperature is less than 60 C 32 F Coolant Temp is less than 60 C 140 F e The transmission is in Neutral or Park e The Service Brake pedal is not depressed e Throttle 0 e Vehicle Speed 0 mph If intake manifold temperature IMT is less than 9 C 15 F three of the cylinders will be shut off upon reaching 1200 rpm creating a slight change in engine sound which is normal Thus the engine has to work to overcome the three dead cylinders This allows the engine to create increased heat in the cooling system allowing more rapid warm up Either feature will abort when any one of the following occurs e The automatic transmission is placed in gear forward or reverse e The service brake pedal is depressed e Throttle position is greater than 0 e Vehicle speed is greater than 0 mph e Coolant temperature is greater than 79 C 175 F Performance enhancement for severe co
94. ch due to the application of a higher than specified clamp load Breakage of the upper control arm fasteners could cause the axle to rotate forward under braking conditions This rotation could twist the steering linkage and possibly separate the brake lines increasing the risk of a crash Dealers will replace the upper control arm bolts and nuts REAR AXLE SPACER PLATE Recall 966 2001 BR BE Dodge Ram Truck Quad Cab equipped with a camper package and overload springs manufactured in July 2000 The rear axle spacer plate could lead to deformation of the upper spring plate during assembly of the axle to the vehicle resulting a soft joint The soft joint could cause the rear axle U bolts to lose clamp load resulting in displacement of the rear axle and a loss of vehicle control This could increase the risk of a crash Dealers will remove the spacer plates and the spring plates will be replaced THROTTLE CABLE Recall 970 1994 1996 BR BE Dodge Ram Truck with diesel engine manufactured from July 1993 to July 1996 On certain pickup trucks the throttle cable could unravel fray or break resulting in a loss of throttle control A throttle that does not return to idle could result in unexpected acceleration increasing the risk of a crash Dealers will inspect and replace the throttle cable and upper bell crank lever Brake Hose ABS Sensor Wire Assembly Clearance Recall 971 2000 BR BE Dodge Ram Truck with ABS manufactur
95. ck This recall applies only to the above vehicles equipped with a 6 7 liter diesel engine sale code ETJ The Engine Control Module ECM software program on the above vehicles may cause illumination of the Malfunction Indicator Lamp MIL when no problem exists or under certain conditions allow heavy sooting of the turbocharger exhaust gas recirculation valve and diesel particulate filter Heavy sooting could damage emissions components and result in increased emissions Repair The Engine Control Module must be reprogrammed flashed The bulletin describes the service procedure that the dealership technician is to follow Using the dealership s scan tools the time allowance for the reprogramming operation is less than one hour As a part of the recall and ECM update the technician has to verify that the previous emissions recall recall G30 October 2007 has been performed The G30 recall contains software that must be installed to prevent damage to the ECM There are no parts involved in the J35 recall notice A Publication of the TURBO DIESEL REGISTER SAFETY RECALL K08 WIRELESS IGNITION NODE RECEIVER Date August 2010 Models 10 DJ Ram Truck 2500 Series 10 D2 Ram Truck 3500 Series This recall applies only to the above vehicles built at Saltillo Assembly Plant G in the 11th VIN position equipped with an automatic transmission from January 6 2010 through February 16 2010 This recall also affected other Ch
96. cle radio system radio radio amplifier antenna antenna lead Do not replace any radio system component in an attempt to address this condition Remote start system Diagnostic chart for antenna This bulletin involves a diagnostic chart that may be used to aid the technician with the diagnosis of the antenna on an originally equipped factory installed remote start system This bulletin applies to vehicles with an original equipment remote start system sales code XBM The customer may notice that the signal range of the remote keyless entry system is reduced less than 100 feet This condition may be due to the RKE antenna The diagnostic flow chart is provided as a diagnostic aid for dealer technicians Flash Sunroof module excessive ignition off draw pop in radio with ignition off dome lamp flickers and may not go off This bulletin involves selectively erasing and reprogramming the Sunroof Motor Module with new software MOPAR remote start system RKE intermittent operation or alarm may sound This bulletin involves the installation of a Mopar remote start system service repair kit CATEGORY 8 ELECTRICAL continued 08 007 08 REV A 7 4 08 08 028 08 9 18 08 08 035 08 11 21 08 07 08 08 DR DH DC D1 07 09 DH D1 CATEGORY 9 Engine does not crank or start due to electronic lockup of the remote key module This bulletin applies to vehicles built on or before May 05 2008 The custome
97. cle by several inches proving clearance so that most customers can attach their fifth wheel or goose neck trailer to the trailer hitch turntable BRAKES TSB MODELS 05 002 01 01 3 9 01 CATEGORY 8 SUBJECT DESCRIPTION Parking brake pedal adjustment This bulletin applies to 2500 3500 series Ram trucks with four wheel disc brakes built before November 20 2000 Parking brake cable appears to be mis adjusted which may cause the parking brake lamp to remain illuminated even after the parking brake pedal has been released The parking brake system however is not mis adjusted and functions normally Install new parking brake cables ELECTRICAL TSB MODELS 08 010 01 94 02 5 25 01 CATEGORY 9 SUBJECT DESCRIPTION Airbag clock spring service When servicing any airbag system it is essential to follow the proper Service Manual and or Diagnostic Manual procedures for diagnosing testing and replacing of any component Do not use silicone or any other lubricant spray on or near the clock spring Lubricants are often used in the clock spring area of the steering column to eliminate noise Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered This includes clock spring replacement steering column service HVAC service steering gear service and front suspension crossmember service ENGINE TSB MODELS 09 002 01 98
98. ction the condition is caused by a programming error The condition is corrected by following the operational sequence outlined in the TSB Erratic coolant temperature gauge reading The cooling system on the Cummins diesel engine equipped vehicles provide for capacity and protection at high GCWR THe large capacity can cause slower than normal warm up Also temperature gauge reading fluctuations are normal Fuel gauge innaccuracy Too much reserve fuel in the tank when the gauge indicates empty may be the fault of an incorrect sending unit The repair involves a wiring harness and sending unit change Service procedure for the stop light switch connector An information only bulletin showing the disconnect procedure of the stop light switch Trailer tow wiring installation The information only bulletin gives guidelines for proper wiring of trailer tow wiring packages Speedometer reading fluctuates and or the speed control disengages The condition may be caused by spread female connectors at the 2 way distance sensor connector Inspect and replace as necessary Fuel reads low when fuel tank is full If fuel gauge does not read full after filling the fuel tank the problem may be an incorrectly calibrated fuel sealing unit Repair and replace as necessary ENGINE SUBJECT DESCRIPTION Diagnosing oil consumption The concern is an operator report of greater than one quart per one thousand miles Variations in oil level are likely poss
99. cycle What is an owner to do purchase the end of the old generation on be the first on the block with the new Both scenarios have their benefits Regardless of you choice lII try to keep you up to date with our annual TSB review Robert Patton TDR Staff A Publication of the TURBO DIESEL REGISTER RECALL NOTICES 2012 SAFETY RECALL L16 LEFT TIE ROD Date March 2012 Models Production 08 09 DH 2500 4x4 08 09 D1 3500 4x4 10 11 DJ 2500 4x4 10 11 D2 3500 4x4 08 10 DC 3500 Cab Chassis 11 DD 3500 Cab Chassis a Ye wae This recall applies only to the above vehicles built at the Saltillo Assembly Plant G in the 11th VIN Position from February 14 2008 through March 28 2011 Models Service Parts 03 04 DR 2500 3500 4x4 06 08 D1 3500 4x4 07 08 DC 3500 Cab Chassis 05 08 DH 2500 4x4 05 DH 3500 4x4 This recall applies only to the above vehicles that were built between July 12 2002 and February 13 2011 and had the steering linkage replaced with Mopar service parts after February 14 2008 Subject The left tie rod ball stud on about 208 000 of the above vehicles may fracture under certain driving conditions This could cause a loss of directional control and or a crash without warning The same vehicles may also have a loose front track bar bolt This could cause a rattle or banging noise under certain driving conditions Repair The vehicle must be inspected f
100. d 3 2 downshifts These new shift points keep the engine at or near peak horsepower to avoid this performance issue 23 006 10 10 D2 DJ This bulletin involves flash reprogramming the transmission control module TCM with new 3 10 10 software CATEGORY 23 BODY 23 003 12 All Chrysler vehicles Hood creaking and squeaking sound 2 07 12 This bulletin applies to D2 DJ vehicles built before January 29 2010 The customer may experience a creaking and or squeaking sound from the hood area when turning the vehicle and or going over rough terrain This repair involves adding anti squeak tape to the hood A Publication of the TURBO DIESEL REGISTER 91 CATEGORY 23 BODY continued 23 019 12 6 19 12 12 DJ DD D2 DP Light to moderate paint surface imperfections on factory applied paint finish This information only bulletin applies to vehicles with isolated light to moderate paint surface imperfections scratches bird dropping stains chemical etching etc on factory applied paint The bulletin outlines a list of Meguiar s products that can be used to clean the paint Service personnel are reminded to always begin with the least aggressive method to remove a paint condition Work one section at a time Always work on a cool paint surface free of bonded surface contaminants Should above surface defects be present prepare the surface with Meguiar s Detailing Clay Editor s Comments Paint Detailing When it com
101. d gear limp In mode as a result of the DTC The Limp In mode may last until the vehicle owner cycles the ignition key The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive The MIL is caused by an increase in hydraulic pressure The increased hydraulic pressure is the result of a new valve body machining process which entered into production January 1 1998 This condition will occur most often with vehicles that were built between January 1 1998 and December 18 1998 Vehicles built prior to January 1 1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1 1998 This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module PCN with new software CATEGORY 21 TRANSMISSION continued 21 08 00 99 00 BR 09 01 00 21 12 00 00 01 BR 09 15 00 CATEGORY 23 47RE delayed TCC lock up and or MIL P1740 TCC or O D Solenoid Performance This information applies to vehicles build for the California market NAE equipped with a 5 9L 24V diesel engine and built between March 2 1999 and October 1 1999 The customer may experience a delayed torque converter clutch engagement lock up This condition may illuminate the Malfunction Indicator Lamp MIL due to Diagnostic Trouble Code DTC P 1740 TCC or O D Solenoid Performance In some s
102. d on right channel speakers Infinity RAY cassette with equalizer system may loose the sound of right side speakers RAS code radios are not affected An exchange radio is the repair Weak sounding horn The bulletin discusses an upgrade from a single horn to a dual horn system Fuel gauge sticks The bulletin covers replacing the fuel pump module if the fuel gauge intermittently sticks at full with less than full capacity Battery drain on vehicles equipped with trailer tow package Water may collect in the 7 pin trailer tow connector housing causing corrosion Exterior or interior lights may erratically operate regardless of switch operation Inspect the tow connector and notch the connector to allow for drain Diesel secondary battery does not charge vehicles built prior to 2 14 94 Corrosion at battery clamp to secondary battery may prevent charging Inspect test and replace battery clamp bolt if necessary Fuel gauge inaccuracy If the fuel gauge reads inaccurately too much reserve when the tank gauge reads empty a revised fuel sending unit may be necessary Trailer tow brake wire location An information only bulletin showing the wiring provisions for an electric brake actuator Power mirror vibration On vehicles equipped with power mirrors built prior to 9 18 94 this TSB discusses the diagnosis and repair for excessive vibration blurred images Poor AM radio reception On vehicles built prior to 12 01 93 poor AM rece
103. d up to 1500 rpm in order to improve cab heat The feature must be enabled using the DRBIII If the vehicle operator would like to have the feature enabled perform the repair procedure which involves erasing and reprogramming the Cummins ECM with new software White smoke engine stumble misfire or flat spot in engine performance This bulletin applies to vehicles equipped with a Cummins Turbo Diesel engine sales code ETH with an engine serial number 57130285 through and including 57149668 and the engine date of manufacture 12 10 2003 through and including 2 2 2004 The vehicle operator may describe e White smoke during no load engine acceleration between 2800 and 3000 rpm e Engine stumble misfire or flat spot during moderate accelerations between 1500 and 2500 rpm May be accompanied by white smoke e During cold ambient temperatures 30 or below white smoke and or engine stumble when engine is started after an extended cold soak e During cold ambient temperatures 30 or below white smoke when restarting engine that has not yet reached normal operating temperature If the vehicle operator describes or the technician experiences the problem perform the repair procedure which involves erasing and reprogramming the Cummins ECM with new software 61 CATEGORY 18 VEHICLE PERFORMANCE continued 18 033 04 8 20 04 18 041 05 12 20 05 18 001 06 Rev A 7 12 06 18 003 06 Rev A 09 27 06 18 005 06 Rev B 05 31 06 18 022 0
104. dal buzzing noise with cruise control engaged 5 8 98 This bulletin applies to vehicles equipped with the 5 9L 24 valve Cummins diesel engine If an audible buzz is coming from the accelerator pedal when the cruise control is engaged a road test diagnosis is described If necessary a re routing of the accelerator cable is described CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS SUBJECT DESCRIPTION 18 06 98 94 98 BR Hard starting diagnosis 2 27 98 This information applies to the 5 9L Cummins mechanically injected 12 valve diesel The discussion covers hard or no start diagnosis and repair 18 07 98 94 98 BR Effects of incorrect idle speed 2 27 98 This information applies to the 5 9L Cummins mechanically injected 12 valve diesel Incorrect idle adjustments either too high or low may cause many different customer concerns The bulletin gives a list of items that explain the condition symptoms associated with incorrect idle settings along with component checks and specifications to set it properly N 8 A Publication of the TURBO DIESEL REGISTER CATEGORY 21 TRANSMISSION TSB MODELS 21 10 98 94 99 BR Rev A 9 25 98 CATEGORY 23 SUBJECT DESCRIPTION Loss of fifth gear This bulletin supersedes technical service bulletin 21 10 98 with an effective date of September 11 1998 This bulletin applies to vehicles equipped with a NV 4500 manual transmission and the 8 0L V10 gas engine or the 5
105. diesel engine built after March 27 1998 engine serial number 56443872 Owners of these vehicles may experience engine oil overflow from the front crankcase breather when the vehicle is oper ated off road on an extreme downhill grade 37 5 or 22 slope grade Operation of this type for extended periods of time can cause enough engine oil depletion to damage the engine A kit containing all components necessary to eliminate the oil overflow has been made available If the condition exists perform the repair procedure outlined in this bulletin The repair involves the addition of a new breather kit Engine knock or rattle sound when climbing a long grade and towing a heavy trailer This bulletin applies to 1998 2002 Ram trucks equipped with the 24 valve Cummins diesel en gine sales code ETC or ETH Owners may experience an engine knock or rattle sound when climbing a long grade while towing a heavy trailer If the condition exists replace the engine thermostat as outlined in the service manual Note Mopar 05015708AC is to be used exclusively for this service bulletin Use thermostat 05015708AB for all other 24 viave Cummins thermostat repairs Accessory drive belt chirp at shutdown This bulletin applies to vehicles with diesel engine sales code ETH A chirping sound may be heard coming from the accessory drive belt when the engine is shut down If a customer indicates that the condition is present the bulletin directs the technician to inst
106. discussed is a high pitched squeal coming from the rear brakes when the brakes are applied The repair procedure involves installing revised rear brake shoes 05 06 00 00 01 BR Front brake caliper anti rattle clip retainer service procedures 06 09 00 This bulletin applies to vehicles built before June 26 2000 Vehicles built between April 19 2000 and June 26 2000 were built with a front brake caliper anti rattle clip retainer This Technical Service Bulletin provides the installation procedures for the retainer CATEGORY 8 ELECTRICAL TSB MODELS SUBJECT DESCRIPTION 08 05 00 99 BR Intermittent operation of the instrument cluster 04 21 00 The needle of the instrument cluster gauges may intermittently drop to zero and or the telltale lamps such as the AIRBAG warning lamp may intermittently come on The bulletin involves replacing the instrument cluster wire harness connector and associated wire terminals 08 08 00 99 00 BR Inoperative or intermittent remote keyless entry RKE transmitter 03 17 00 The problem described is an inoperative RKE transmitter This condition may be intermittent and will have similar symptoms to a dead transmitter battery This bulletin discusses replacing and reprogramming the RKE transmitter 08 11 00 94 00 BR Recordable compact discs used in automotive CD players 03 24 00 Some recordable compact disc media such as CD R and CD RW may not comply with the standard
107. distinct detent will be felt to overcome the pre hold position On 06 and 07 DR vehicles the circuits fed by the IOD fuse are Radio EVIC Wireless Control Module Hands Free Module Satellite Radio Video Screen CCN wake up with ignition off Underhood Lamp and CCN Interior Lighting CATEGORY 8 ELECTRICAL continued 08 020 06 5 5 06 08 021 06 Rev A 10 13 06 54 06 DR 06 Overhead console average fuel economy display This information only bulletin discusses the calculation method used by the truck s average fuel economy display On 06 vehicles the calculation has been changed to use the last displayed average fuel economy as a starting point for the calculation after a reset The average fuel economy will then be adjusted from that point If the display read 21 6 mpg at the time the reset was activated the new display will start at 21 6 mpg and would change from that point depending on the current fuel usage This was done to eliminate the extreme variations caused by very high or low fuel usage at the time of the reset TIPM Flash DTC s indicating short circuits in the wiring on the trailer or no engine crank with DTC P1277 starter control circuit too low This bulletin supersedes technical service bulletin 08 021 06 dated May 10 2006 This bulletin involves a discussion and reprogramming of the totally integrated power module TIPM This bulletin applies to vehicles built prior to April
108. dor results The repair involves cleaning the evaporator with Mopar aerosol cleaner 25 TSBs Issued During 1998 CATEGORY 5 BRAKES TSB MODELS SUBJECT DESCRIPTION 05 04 98 97 99 BR Height sensing proportioning valve removal 6 12 98 This procedure should only be performed on 2500 series 4x4 vehicles that are continuously operated at 75 or greater GVW and have had their rear suspension altered The bulletin describes a procedure the dealer should follow in the removal of a rear height sensing proportioning valve Removal of the proportioning valve should help prolong front brake life CATEGORY 6 CLUTCH TSB MODELS SUBJECT DESCRIPTION 06 01 98 97 98 BR Release fork orientation 6 19 98 This bulletin applies to vehicles equipped with an NV4500 manual transmission and either the 8 0L gas engine or the 5 9L Cummins diesel engine The bulletin covers the proper installation of the clutch release fork CATEGORY 7 COOLING TSB MODELS SUBJECT DESCRIPTION 07 08 98 98 99 BR Diesel engine overheating 12 11 98 This information applies to vehicles equipped with a 24 valve Cummins diesel engine with an engine serial number ESN 56512007 or prior This bulletin involves replacing the thermostat with a revised part 05015090AA CATEGORY 8 ELECTRICAL TSB MODELS SUBJECT DESCRIPTION 08 09 98 94 98 BR Driver side power mirror vibrates while driving 3 13 98 This bulletin
109. drive is off The repair involves reprogramming the powertrain control module with new software Transfer case shifter buzz or clatter A buzz or clatter may be heard from the 4x4 shifter at an engine speed of approximately 2000 rpm The repair involves the addition of an insulating plastic gate liner to the transfer case shifter Quick connect removal and reconnect procedure The information only bulletin describes the repair procedure for removal reconnect of the transmission cooler line fitting on trucks built after 3 20 95 and superseded bulletin 21 02 95 3 31 95 BODY TSB MODELS 23 01 96 94 96 BR 1 5 96 23 02 96 94 96 BR 1 19 96 23 09 96 96 BR 2 2 96 Clubcab with a J in the VIN at position 11 and built prior to 10 6 95 23 21 96 94 96 BR 3 29 96 23 27 96 96 BR 4 19 96 23 29 96 94 96 BR 5 10 96 23 45 96 94 96 BR 8 2 96 23 46 96 94 96 BR 8 2 96 A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION Replacement cargo box information This information bulletin list the revised part numbers for the 6 5 ft and 8 0 ft cargo box with a reinforced front box floor Creak or tick noise from right side instrument panel The noise can be reproduced by pushing on the instrument panel at the shelf above the glove box door The repair involves the removal of a 3 10 rivet Seatbelt buckle difficult to engage with one hand The
110. e TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE continued 18 037 07 07 DH D1 Rev A 07 20 07 18 013 08 07 08 3 13 08 18 013 08 07 09 DH D1 REV A 12 4 08 A Publication of the TURBO DIESEL REGISTER In October of 07 this TSB and the number of fault codes addressed by the reprogramming of the ECM was superseded by a recall Recall G30 of all 6 7 liter engines built to that date The TSB 18 033 07 was left in the magazine to give 6 7 liter owners data to see what the Recall G30 scope of work entailed Then in December of 08 the G30 recall and the TSB 18 013 08 that described the proper repair technique were updated again by TSB 18 013 08A 68RFE Transmission DTC P0868 low line pressure This bulletin applies to vehicles equipped with a 68RFE automatic transmission sale code DG7 built on or before April 30 2007 The customer may experience a malfunction indicator lamp MIL illumination due to diagnostic trouble code DTC P0868 Low Line Pressure This condition may be due to the transmission control module TCM software or to a hardware circuit in the TCM This bulletin involves checking the transmission control module TCM to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software Engine system and exhaust aftertreatment system enhancements This bulletin applies to vehicles equipped with a Cummins 6 7 liter engine sales code
111. e above vehicles built through May 27 2005 Incorrect front coil springs may have been installed on about 8 100 of the above trucks front suspension This may cause the front suspension to bottom out prematurely which can reduce ride quality Repair Both front suspension coil springs must be replaced SAFETY RECALL E17 OUT OF PARK ALARM SYSTEM Date March 2006 Models 03 04 DR 05 DH This recall applies only to the vehicles equipped with a 5 9L diesel engine 6 or C in the eighth VIN Position and an automatic transmission sales code DGP or DG8 In certain circumstances when a driver has not placed the shifter lever fully into the Park position and leaves the engine running the vehicle may unexpectedly move rearward after seeming to be stable Unintended rearward movement of a vehicle could injure those in and or near the vehicle Repair An Out of Park alarm system must be installed on the vehicle The alarm system will beep the horn and flash the headlamps and shift indicator if a driver tries to exit a running vehicle without fully placing the shifter into the Park position SAFETY RECALL F05 ANTILOCK BRAKE SYSTEM CONTROL MODULE Date July 2006 Models 06 D1 Dodge Ram Pickup 3500 Series 06 DH Dodge Ram Pickup 1500 Mega Cab and 2500 Series This recall applies only to the above vehicles equipped with a four wheel Antilock Brake System sales code BGK or BRT built from September 12
112. e based on the vehicle model 15 CATEGORY 8 TSBs Issued During 2010 ELECTRICAL TSB MODEL 08 004 10 10 D1 3 2 10 10 DJ 09 10 DS 09 018 10 10 DJ 7 29 10 09 10 DS CATEGORY 9 SUBJECT DESCRIPTION Radio video disable update This information only bulletin describes the programming process used for allowing the front seat video option to be displayed if the vehicle is in park automatic or the emergency brake is on manual Left turn signal on trailer may be inoperative When verifying trailer turn signal function prior to towing a trailer the customer may experience a non functional left trailer turn signal Check connector terminal number one If there is silicone in the connector use a suitable tool such as a straight blade Exacto knife to scrape the silicone off the outside of the number one left terminal ENGINE TSB MODEL 09 001 10 All diesel models 7 2 10 CATEGORY 14 SUBJECT DESCRIPTION Dust out diagnosis for Cummins diesel engines This information only bulletin involves proper inspection procedures to determine engine failure due to dust out condition Engines damaged due to the infiltration of dirt and or debris through the air intake system are not warrantable FUEL TSB MODEL 14 001 10 03 09 DH D1 2 2 10 14 002 10 03 09 DH D1 2 11 10 07 09 DC SUBJECT DESCRIPTION Electronic fuel control actuator FCA available for service New diag
113. e bug deflector or air dam located on the front of the hood may become loose and rattle The deflector could become dislodged in an automatic car wash The repair involves replacing the bug deflector fasteners Binding front power window This bulletin applies to vehicles equipped with trailer tow mirrors sales code GPD or GPG Vehicle owners may experience the power window on the front door binding or slow to operate The corrective action involves lubricating the window channel and installing a spacer under the outside mirror Improved secondary door seal Mud or dirt may accumulate on the rocker panel causing customers to complain that their clothing gets dirty when they enter or exit the vehicle This bulletin involves installing a new lower secondary door seal Low gloss interior trim This information only bulletin discusses that all Chrysler Dodge and Jeep vehicles are designed with a low gloss interior trim This low gloss finish maintains pleasing aesthetics and minimizes glare of the instrument panel into the windshield This low gloss finish should not be altered with a medium or high gloss interior treatment solution such as MOPAR Protector s or other Armor All like products Instead MOPAR Satin Select part number 05174395AA which has been specifically developed to remove minor surface contamination and maintain the low gloss appearance should be used for interior trim treatment Drip rail door seal torn The drip rail
114. e checked per the procedure in the appropriate Powertrain Diagnostic Procedure Manual Diagnostic Trouble Code 33 A C clutch relay circuit will be present when either of these conditions are caused by the PCM It is important to perform the complete test sequence because there are other A C clutch relay circuit components that could also cause or contribute to the condition Air conditioner compressor noise A growling noise may be heard with the compressor running Diagnose the condition as outlined and perform the repair procedure if necessary The repair involves installing a revised compressor valve plate assembly MISCELLANEOUS TSB MODELS 26 04 94 All 10 28 94 A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION Diagnostic procedure manuals The bulletin gives a current list of available diagnostic procedure manuals These manuals provide system information step by step trouble shooting procedures diagnostic and driveability tests along with diagrams illustrations and helpful charts to find and fix problems on Chrysler Corporation vehicles These manuals can be ordered by calling 1 800 626 1523 TSBs Issued During 1996 CATEGORY 2 FRONT SUSPENSION TSB MODELS 02 01 96A 94 96 BR 5 31 96 02 03 96 94 96 BR 5 31 96 02 04 96 94 96 BR 6 21 96 Two wheel drive 2WD 02 06 96 94 97 BR 11 29 96 4x4 only CATEGORY 3 SUBJECT DESCRIPTION Camper Special service kit
115. e process of cleaning the turbocharger using Cummins Engine Update Kit 10138 UPD to address excess soot accumulation The procedure cleans the internal components on the exhaust side of the turbocharger The bulletin goes hand in hand with TSBs 11 005 08 and 11 002 07 for detailed turbocharger engine and exhaust aftertreatment system repair procedures Inspections and test for the turbocharger on the Cummins 6 7 liter engine The customer may experience a malfunction indicator lamp MIL illumination due to diagnostic trouble code DTC P2262 Turbocharger Boost Pressure Not Detected Mechanical If further codes of P1451 P2463 or P242F are present the technician is referred to the repair procedure listed in TSB 11 002 07 If the codes are not present the repair and cleaning procedures in this 8 page bulletin and TSB 11 001 08 are to be performed 37 CATEGORY 11 EXHAUST continued 11 001 09 07 09 DH D1 7 23 09 11 002 09 07 09 D1 DH 8 5 09 CATEGORY 13 Diesel Particulate Filter Diagnosis and repair of DTC s P1451 P200C P242F or black smoke from exhaust This bulletin applies to vehicles equipped with a Cummins 6 7 liter engine sales code ETJ The customer may experience a malfunction indicator lamp MIL illumination warning chime and an overhead electronic vehicle information center EVIC message regarding the aftertreatment system and or black smoke from the exhaust and or a no start condition Further i
116. e road This clunk like sound is sometimes described as being similar to the sound that loose lumber may make when loose boards strike each other This condition is more noticeable during cold ambient conditions below 40 F and at lower vehicle speeds when background noise is less The sound may come from the front and or rear shock absorbers This condition is due to internal components within the vehicle shock absorber and the bulletin describes the replacement procedure AXLE DRIVELINE TSB 03 001 02 2 11 02 03 002 02 7 1 02 03 003 04 6 15 04 MODELS 02 BR BE 02 03 DR 03 04 DR SUBJECT DESCRIPTION Front axle disconnect system This bulletin involves a mid 2002 model year deletion of the front axle disconnect system on 2002 BE BR 2500 and 3500 Ram Trucks This change effects the front axle transfer case and engine headlamp and dash wiring harnesses The bulletin applies to 2500 and 3500 BE BR Ram trucks built after January 4 2002 and equipped with front axles with the following part numbers 52070136A0 52070137A0O 52070138AP and 52070139A0 The vehicles involved will retain Shift On the Fly SFO capability however with this change the front driveshaft will now turn continuously when the vehicle is being driven Due to the timing of this change this information is not reflected in the Service Manual and a future release will outline service procedures Use of synthetic rear a
117. e the cause of the inoperative speed control Perform the repair as outlined in the bulletin Inoperative CD player as a part of sales code RAZ radio This bulletin supersedes TSB 08 27 97 dated 7 18 97 The bulletin applies to 97 vehicles equipped with an AM FM cassette CD player sales code RAZ radio A condition is described where the CD player may become inoperative and will not accept the CD when attempting to insert the disk into the radio The condition can be intermittent and may occur more often in hotter ambient temperatures The AM FM radio and cassette portion of the radio will continue to operate normally The repair involves an exchange of the unit as supplied by Chryslers repair center Ashtray receiver lamp degrades from blue green to bright white The ash receiver lamp when illuminated may change from a blue green illumination to a bright white illumination This change will occur over a long period of time of continuous use This bulletin involves replacing the ash receiver lamp and housing with revised parts NHTSA authorized airbag deactivation for medical necessity This information only bulletin describes the procedures necessary to deactivate airbags authorized by NHTSA Airbag deactivation is a customer pay procedure not covered under the provisions of warranty Dead battery from ignition off draw IOD The problem described is a dead battery due to the glove box lamp remaining illuminated when the glove bo
118. e vehicle may exhibit a bucking or jerking condition while under light acceleration or while driving at steady state speeds The vehicle may be in a loaded or unloaded state when the bucking or jerking occurs This condition results from the sensitivity of the throttle linkage to driver input The repair procedure involves replacement of the throttle linkage levers with revised parts CATEGORY 19 STEERING TSB MODELS 19 08 97 96 97 BR 5 30 97 19 10 97 94 98 BR 8 15 97 19 16 97 94 97 BR 11 28 97 CATEGORY 21 SUBJECT DESCRIPTION Clunk rattle felt in steering column wheel This bulletin supersedes TSB 19 01 96 dated 2 9 96 for 1996 model year vehicles This bulletin applies to all vehicles built in the United States first digit of VIN 1 and vehicles built in Mexico first digit of VIN 3 before Mar 3 1997 The condition to be examined is a clunk or rattle that maybe felt in the steering wheel column during slow turns rough road driving and stops The diagnosis involves inspection of the front suspension and steering components including a check of all fasteners for proper torque as specified in the appropriate Service Manual The repair procedure involves replacement of the steering intermediate shaft Steering wander If when driving on a straight road a higher than normal steering wheel movement perceived as excessive play is required to keep the vehicle going straight or if over compensating the s
119. ea of the steering wheel while turning The sound is associated with rotation fo the steering wheel or may be heard while going over bumps in the road The repair involves installing new lock housing attaching screws CATEGORY 21 TRANSMISSION TSB MODELS 21 02 00 99 00 BR 03 10 00 21 04 00 96 99 BR 06 30 00 A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION 47RE transmission delayed upshift or no TCC engagement between 30 and 50 MPH This bulletin applies to vehicles equipped with a federal market 5 9L 24V diesel engine and built between March 2 1999 and October 1 1999 The customer may experience a condition where the transmission may seem to have a delayed 3 4 upshift while moderately accelerating from 30 to 50 MPH The customer may also note high engine rpm s while operating in third or fourth gear This condition may be caused by a delay in the engagement of the transmission torque converter clutch torque converter lockup The repair involves the replacement of the transmission valve body upper housing separator plate Erroneous MIL illumination for P1763 Transmission Governor Pressure Sensor Volts Too High Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code DTC of P1763 Transmission Governor Pressure Sensor Volts Too High The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its thir
120. ed from July 1999 To September 1999 Some vehicles may have inadequate clearance between the front tire wheel and the brake hose ABS sensor wire assembly During full lock turns it is possible for the tire or wheel to contact the brake hose ABS sensor wire assembly This could ultimately result in wire damage and or a hole in the brake line affecting brake effectiveness increasing the risk of a crash Dealers will replace the front brake hose assemblies and the ABS sensor wire will be inspected and replaced if necessary CLOCKSPRING Recall 982 2001 BR BE Dodge Ram Truck manufactured from May 2000 To October 2000 Sound deadener material internal to the clockspring could become detached from the clockspring cover and housing When this occurs the material could interfere with the clockspring ribbon and cause an open circuit The driver air bag system will become disabled and the air bag warning lamp will illuminate on the instrument panel Dealers will replace the clockspring assembly CUSTOMER SATISFACTION NOTIFICATION NO C44 TRANSMISSION COOLER LINE Date February 2004 Models 03 04 DR This notification applies only to trucks equipped with a 5 9 liter Cummins diesel engine sales code ETC or ETH and an automatic transmission sales code DG8 or DGP built through November 24 2003 The transmission cooler line on about 97 000 of the above vehicles can transmit high pressure pulses when the vehicle is operated at he
121. ed by NHTSA Airbag deactivation is a customer pay procedure Radio Interference to from two way radio receivers Customers may complain of intermittent poor reception on their two way radios This condition does not affect the operation of any AM or FM band radio Radio receivers from approximately 20 MHZ to 174 MHZ may be susceptible to Radio Frequency Interference RFI from the fuel pump module s motor If there is RFI the bulletin describes the installation of an RFI filter in series with the electric fuel pump Instrument cluster bezel breaks when removed This information only bulletin is a reminder that the instrument cluster bezel is retained by several snap clip retainers and one screw located underneath the power outlet access door It is imperative that this singular screw is removed prior to attempting to remove the instrument cluster bezel from the instrument cluster Use of two digit calendar year codes in automotive computers There has been a great deal of recent media attention regarding the turn of the century year 2000 Y2K etc and the effect it will have on computers that have used two digit calendar year coding in their programming Questions are arising regarding computers used in automotive applications and the effect year 2000 will have on them Two digit calendar year codes have not been used in any Chrysler automotive onboard applications and no problems related to use of two digit coding for calendar years are an
122. ed by vinyl interior trim material releasing gasses that adhere to the glass The condition lessens as the vehicle gets older Wind noise at front of door Inspect the vehicle for the appropriate seal If not present perform the repair installation procedure Door fit at roof line The top of the door should project higher than the roof panel Do not attempt a repair if the door falls within the overflush 1 3 mm condition A Publication of the TURBO DIESEL REGISTER CATEGORY 23 BODY continued 23 36 94 94 BR 4 22 94 23 39 94 94 BR 5 6 94 23 40 94 A 94 BR 5 6 94 23 41 94 94 BR 5 13 94 23 45 94 94 BR 6 3 94 23 49 94 94 BR 7 1194 23 51 94 94 BR 7 1194 23 60 94 94 BR 8 12 94 23 63 94 89 93 AD 8 26 94 23 68 94 94 95 BR 9 30 94 23 71 94 95 BR 10 7 94 23 73 94 94 BR 10 7 94 23 95 94 A 94 95 BR 12 30 94 23 98 94 94 BR 12 23 94 A Publication of the TURBO DIESEL REGISTER Front door to windshield moulding squeak creak A noise from the front of door plastic windshield moulding can occur The correction is to install anti friction tape to the inside edge of the doors Pickup box floor rattle The bulletin involves applying sealer to the pickup box floor at the crossmember Door glass rattle If the door glass rattles when the door is closed and the window is open the bulletin describes the diagnosis and repair of
123. ed during the manufacturing process there is a tendency for the extra coating to flake off Flakes may blow from the vents when the fan is turned on The bulletin is issued for information only A C evaporator odor A musty odor may be emitted from the air conditioner ducts The odor is most noticeable when the A C is first turned on after the system has been left off evernight or longer The odor is a result of foreign material accumulating in the evaporator area The bulletin involves cleaning and disinfecting the A C evaporator and housing A Publication of the TURBO DIESEL REGISTER CATEGORY 24 AIR CONDITIONING continued 24 17 94 91 93 AD 11 18 94 94 95 BR 24 27 93 91 93 AD 11 19 93 94 BR CATEGORY 26 A C evaporation freeze up or lack of cooling on cycling clutch of air conditioning system Loss of A C airflow and or cooling while the blower fan continues to operate may occur This bulletin discusses the role of the powertrain control module in the A C system The electrical signal from the A C cycling clutch switch passes through the Powertrain Control Module PCM to engage and disengage the A C clutch relay If the PCM is not properly disengaging the A C clutch via the relay the compressor will stay on continuously and result in evaporator freeze up Also the PCM may not energize the A C clutch relay at all This condition results in the lack of cooling from the A C system The PCM should b
124. ed or an erroneous alarm The correction is a reflash of the FCM Electro mechanical instrument cluster MIC erroneous indicator lamps Three conditions have been identified which may be caused by communication errors between the electro mechanical instrument cluster MIC and other electronic modules on the vehicle 1 An intermittent false Check Gauges on diesel engine equipped vehicles 2 An intermittent false chime and Low Wash indicator 3 A Trans Temp indicator on a manual transmissions equipped vehicle This bulletin involves selectively erasing and reprogramming the MIC with new software Alternator mounting bracket cracked This bulletin applies to vehicles equipped with a 5 9L 24 valve diesel engine sales codes ETC or ETH and built on or before February 13 2003 with engine serial numbers prior to 57013271 The problem is that the vehicle operator may experience an accessory drive belt squeal during normal driving conditions This bulletin describes how to replace the alternator support bracket with a revised bracket Lamp out indicator with aftermarket pickup box installation This information only bulletin discusses situations where an aftermarket utility box is installed after the removal of the original equipment pickup box Under the circumstances the lamp out indicator may illuminate This is due to the use of aftermarket rear stop and turn signal lamps which use a dual filament bulb instead of separate ci
125. ed with a A568RC transmission sales code DG3 all vehicles with a Getrag MP56 sales code DG5 and Grand Cherokees with the diesel engine option ATF 4 is backward compatible with ATF 3 ATF 2 and ATF Additionally ATF 4 can be used to top off vehicles that used ATF 3 ATF 2 or ATF Benefits Better anti wear properties e Improved rust corrosion prevention e Controls oxidation e Eliminates deposits e Controls friction e Retains anti foaming properties e Superior properties for low temperature operation Mopar ATF 4 has exceptional durability However the red dye used in ATF 4 is not permanent as the fluid ages it may become darker or appear brown in color ATF 4 also has a unique odor that may change with age With ATF 4 fluid color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change 68RFE transmission harsh coast downshift and or harsh 2 3 upshift This bulletin applies to vehicles equipped with a 68RFE automatic transmission sale code DG7 built on or before November 6 2007 The customer may experience a harsh downshift from the transmission when coming to a stop When a vehicle stop is initiated from 4th gear around 25mph the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 10mph If the transmission is in 2nd 3rd 5th or 6th gear when the stop is initiated the condition will not be present This may cause the condition to a
126. ent in the repair order that limited warranties do not cover conditions or damage caused by the use of aftermarket components improper maintenance or impact damage can cause steering shimmy or otherwise accelerate the wear of steering components that cause steering shimmy The dealership can inspect steering components that were supplied by the manufacturer for defects in material workmanship and factory preparation and determine if necessary repairs are A Publication of the TURBO DIESEL REGISTER CATEGORY 19 STEERING continued covered under the terms of the warranties applicable to the vehicle Clearly aftermarket items may affect who pays for further inspection e Inspect the vehicle steering components for any damage e Are the tires on the vehicle properly inflated to the correct pressure e Do the tires exhibit a condition of excessive wear cupping or damage e Verify proper wheel and tire balance e Inspect the steering damper e Does the track bar show signs of excessive wear or damage e Do the tie rods show signs of excessive wear or damage Does the drag link show signs of excessive wear or damage e Verify vehicle wheel alignment is within specification and adjust accordingly Do the ball joints show signs of excessive wear or damage Editor s Comments Death Wobble If you spend a day answering the tech line at Geno s Garage you would be surprised at the number of phone calls asking about the Death W
127. entilation DC 52 Gallon Tank 68061341AA Kit Severe Duty Fuel Tank Ventilation D1 DH 35 Gallon Tank 68061342AA Kit Severe Duty Fuel Tank Ventilation D1 DH 34 Gallon Tank 5 9 Liter Changes 5 9 upgraded air filter This filter is similar in design to the current 6 7 liter air filter The part number is 53034249AA Element Air Filter 2003 2007 5 9 liter A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE TSB 18 024 09 12 3 09 Rev A 18 016 10 4 30 10 18 017 10 5 15 10 18 020 10 6 10 10 A Publication of the TURBO DIESEL REGISTER MODEL 07 09 D1 DH 07 08 DH 07 08 D1 06 DH 2500 pickup 5 9 liter 06 D1 3500 pickup 5 9 liter 07 DH 2500 pickup 5 9 liter 07 D1 3500 pickup 5 9 liter 07 DC 3500 Cab Chassis 6 7 liter 07 10 DC 08 10 DM SUBJECT DESCRIPTION Diagnostic and System improvements and improved air filter minder This bulletin supersedes technical service bulletin 18 024 09 dated August 6 2009 This bulletin applies to D1 DH vehicles equipped with a 6 7 liter Cummins engine built before May 5 2009 This bulletin involves selectively erasing and reprogramming the engine control module ECM with new software Pickup trucks equipped with a 6 7 liter Cummins diesel have a number of software improvements available This latest bulletin will include e EGR valve cleaning cycle e DPF Snuffer feature to expand DPF temperat
128. es to detailing a truck or car nothing replaces good lighting a sharp eye and lots of elbow grease Again the TDR and its writers have been there done that and the most recent article on detailing your truck is found in Issue 68 pages 58 65 Shaking motion in left rearview tow mirror assembly This bulletin applies to vehicles built before January 10 2012 This bulletin involves inspecting and if necessary replacing the left rearview tow mirror assembly CATEGORY 25 EMISSIONS CONTROL TSB 25 002 11 12 6 11 25 003 11 12 6 11 25 001 12 5 3 12 25 003 12 8 02 12 MODEL 10 12 DJ D2 11 12 DD DP 10 12 DJ D2 11 12 DD DP 11 12 DD DP SUBJECT DESCRIPTION On board diagnosis OBD monitor readiness Vehicles that fail to pass a state mandated emissions inspection may have certain OBD readiness monitors that have not completely run Anytime an ECM PCM has been replaced or flashed the OBD readiness monitors may need to run again to complete the monitoring process This bulletin describes the necessary steps required to run each monitor Customers may be required to drive the vehicle for an extended period of time in a variety of driving styles to allow all of the OBD monitors to run On board diagnosis OBD monitor readiness Vehicles that fail to pass a state mandated emissions inspection may have certain OBD readiness monitors that have not completely run Anytime an ECM PCM has been replaced
129. es to vehicles equipped with the 5 9L Cummins diesel engine After driving over 200 miles the fuel gauge may read full until the vehicle travels over a bump in the road and then the gauge operates normally This condition may be caused by the float in the fuel pump module sticking and may be difficult to diagnose Perform the repair procedure new fuel pump module if the customer s concern matches the description identified in the Symptom Condition Central timer module software update when a wiper module is replaced This bulletin applies to vehicles equipped with remote keyless entry Due to a design change in MOPAR replacement wiper modules the central timing module must be updated with new software in order to allow the wiper module to function properly The outlined repair procedure must be performed any time the wiper module is replaced Intermittent speaker operation static This bulletin applies to vehicles equipped with the Infinity sound system sales codes RBR RBN and RAZ built before October 1 1999 The condition is intermittent operation static that may occur in any or all speakers The bulletin describes the proper repair CATEGORY 9 TSB MODELS 09 04 99 98 99 BR 07 16 99 CATEGORY 18 ENGINE SUBJECT DESCRIPTION Hard to diagnose noise coming from the engine turbocharger area This bulletin applies to vehicles equipped with a Cummins 5 9L 24V diesel engine built prior to engine serial number ESN 5
130. esidue e For grease stains apply Mopar Multi purpose Cleaner p n 05127532AA to a clean damp cloth and remove the stain Use a fresh damp towel to remove the soap residue Do NOT use any solvents or fabric protectants on Yes Essentials fabric Cracked windshield Windshield cracks caused by an impact from a foreign object i e stone are often difficult to identify The following assessment should be used to verify the presence of an impact chip on the crack If no obvious impact chip is present run a ball point pen along the crack and feel for a slight drop or pit in the glass If a slight drop or pit in the glass is present this indicates a small impact caused the crack If the molding contains a witness mark or dent from an impact inspect under the molding for an impact chip in the same manner Cracks caused by an impact are not warrantable Water leak due to small void in backlite sealer The customer may experience the presence of water on or under the rear area floor carpet This condition is likely due to water leaking past a small void in the adhesive used to retain the backlite glass to the body panel It is recommended that a flowable sealer be applied to seal a small void in the backlite adhesive Glass keeper loose on back power sliding window The customer may notice that the glass keeper on the rear backlite has separated from the glass The bulletin gives directions for the proper repair procedure Trailer Towing Mir
131. fting into overdrive This protects the transmission from damage if the fluid would begin to freeze The PCM will allow overdrive once the ambient temperature has risen approximately 7 above the temperature the ID was inhibited at Transmission shift lever stuck in or blocked out of 5th gear reverse The shift lever does not shift out of 5th or reverse gear position or the shift lever will not go into 5th reverse Diagnose the transmission and if necessary replace the transmission overdrive rail lug shift fork and synchronizer Shift lever contacts instrument panel Inspect the shift lever to transmission stub shaft connection Reseat the lever to the stub shaft if necessary Transmission diagnostic reference supplement To assist in the repair of automatic transmission the information only bulletin lists symptom cause correction information Transmission 4 3 downshift clunk A driveline clunk or harshness occurs during 4 3 coast downshift repair as described in bulletin Shift linkage adjustment The information only bulletin explains how to correct a PRNUL misalignment High effort when shifting from 2WD high to 4WD high in cold temperatures If high effort condition occurs when shifting the transfer case in cold temperatures the bulletin describes the repair The procedure involves a change in the front axle lubricant or possibly a parts component replacement Lack of 3 4 up shift and deep throttle 2 4 up shift A complain
132. fuel filtering of the diesel fuel prior to the fuel injection process Use good quality diesel fuel from a reputable supplier It is recommended that purchase of diesel fuel be made from a service station that is known to dispense a high volume of highway diesel fuel Ultra low sulfur highway diesel fuel is required for use in Dodge Ram trucks equipped with a 6 7 liter diesel engine Amaximum blend of 5 biodiesel B5 is acceptable as long as the biodiesel mixture meets ASTM specification D 975 D 975 grade S 15 and ASTM D6751 A biodiesel fuel blend that is higher than 5 is not acceptable without additional fuel processing because these higher percentage biodiesel blends contain excess amounts of moisture which exceed the water stripping capability of the on engine final fuel filter Should a higher percentage biodiesel fuel be used an auxiliary water stripping filter will be required A maximum blend of 20 biodiesel B20 can be used by government military and commercial fleets who equip their vehicle s with an optional water separator and adhere to the guidelines in the Department of Defense specification A A 59693 Fuel conditioners additives are not recommended and should not be required if you buy good quality fuel and follow cold weather advice supplied in the Owner s Manual CATEGORY 18 TSB MODELS 18 024 02 03 DR 8 12 02 VEHICLE PERFORMANCE SUBJECT DESCRIPTION Incorrect dual wheel identification in VIN m
133. fuse is positioned electrically in the circuit between the component in question and either a relay or the ignition switch The lower amperage fuse will be located either in the underhood Power Distribution Center PDC or in the instrument panel Junction Block The lower amperage fuse is often missing because it was removed erroneously for use in another low current circuit If the lower amperage fuse is open blown then the circuit and component in question must be checked for an electrical short Check to make sure that the open fuse was not exchanged with another fuse or was damaged by an installed accessory Slow acceleration or lack of power while towing or hauling a heavy load This information applies to vehicles equipped with a 5 9L 24V diesel engine built before engine serial number 56587297 with a date of engine manufacture of May 5 1999 This information is available on the engine data plate which is located on the left side of the engine affixed to the gear housing There may be a condition of low power or slow acceleration when towing or when hauling a heavy load This software change to the Cummins CM551 diesel engine controller will increase engine torque Some 1998 BR vehicles equipped with a 5 9L 24V diesel engine may already have the latest software revision Verify that the ECM is at calibration level 98T17 p n s 333034303J 333035303J 333036303J 333037303J If the calibration level is 98T17 then this TSB does not ap
134. g Blow by rings not sealing Oil on turbo dust damage to seal bearing This nine page bulletin supersedes bulletin 09 001 10 dated 7 2 10 and gives the service network an easy to print easy to follow diagnosis procedure The highlights e Major mechanical damage can be caused by fuel fuel injectors up rate kits or programmers Inspect vehicle for any device that adds more power fuel which may damage the engine mechanically Check for any aftermarket power enhancer box or downloader Repairs performed on engines with failures caused by these devices do not qualify for warranty coverage e Inspect for aftermarket cold air performance air filter housing duct work and or air filter type wrong style air filter which may be used in a stock air filter box e Vehicles with extremely large amounts of visible dirt accumulation are candidates for dust out damage if not properly maintained or use of improper filters Engines with excessive cylinder and or ring wear will consume excess oil Look for oil spilled near filler on valve cover which may indicate oil has been or is added often As mentioned the bulletin continues for nine pages that show the cause effect from lack of proper air filtration CATEGORY 9 ENGINE continued Editor s Comments Dust Out If you spend a day answering the tech line at Geno s Garage you would be surprised at the number of phone calls asking about air filters and cold air boxes The staffs answer
135. g gear housing 38 A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE continued The customer may complain of low engine power and or poor performance This engine condition may occur while the automatic transmission is being operated in its overdrive gear This condition may be further aggravated if the customer is using the vehicle for towing purposes The Engine Control Module ECM software on a 2001 Ram Truck equipped with a 24 valve diesel engine is designed to torque manage the power output of the engine This is done to protect the automatic transmission components The revised software calibration restores the power output and improves the vehicle performance in overdrive Note If TSB 18 015 00 Rev A has previously been performed too the vehicle in question then the ECM software has already been revised with the correct calibration to address the above condition The ECM will not require reprogramming The repair procedure involves selectively erasing and reprogramming the Cummins CM551 Engine Control Module ECM with new software calibration versions 56113 59T6 There is no change to the JTEC PCM software CATEGORY 19 STEERING TSB MODELS 19 04 00 94 00 BR 06 09 00 SUBJECT DESCRIPTION Squeaking creaking sound in steering column while turning This bulletin applies to vehicles equipped with non tilt steering columns A squeaking creaking sound may be heard coming from the ar
136. g terminal number 26 from the powertrain control module PCM 76 way connector Front overhead ambient light intermittent operation or inoperable This bulletin applies to vehicles built between February 11 2011 and March 9 2011 If there is intermittent or no operation of the front overhead light this bulletin explains how to remove and repair the light 81 CATEGORY 9 ENGINE TSB MODEL SUBJECT DESCRIPTION 09 004 10 11 DJ D2 DD DP Incorrect engine oil level indicator 11 11 10 Cummins engines are equipped with an engine oil level indicator that identifies a Safe region on the end of the indicator Some vehicles were equipped with an engine oil level indicator end that had Add Cold Hot and Do Not Add increments on the end These engine oil level indicators will need to be replaced This bulletin involves inspecting the engine oil level indicator and replacing it if found to have an incorrect indicator end CATEGORY 13 FRAME amp BUMPERS 13 001 11 10 11 DJ Front axle skid plate to oil pan contact 5 13 11 This bulletin applies to vehicles equipped with 6 7 liter Cummins engine and TRX package sales code AMW built after September 1 2009 and built prior to September 23 2010 The front axle skid plate may contact the oil pan during extreme off road usage The repair involves inspection of the oil pan and if necessary replacement of the front skid plate and oil pan CATEGORY 14 FUEL SYSTEM 14 005 10 10 11 DJ
137. gauge needle to erroneously indicate lower than actual oil pressure A warning chime may sound and the Check Gauges lamp may illuminate The Engine Control Module ECM software has been revised to address this condition Replacing the oil pressure sensor will not correct this condition Engine oil additives supplements Engine oil additives supplements EOS should not be used to enhance engine oil performance Engine oil additives supplements should not be used to extend engine oil change intervals No additive is known to be safe for engine durability and can degrade emission components Additives can contain undesirable materials that harm the long term durability of engines Generally it is not desirable to mix additive packages from different suppliers in the crankcase there have been reports of low temperature of low temperature engine failures caused by additive package incompatibility with such mixtures Engine oil pan gasket sealing This bulletin applies to Ram trucks equipped with the 24 valve diesel engine Repeat oil pan gas ket leaks can occur on 24 valve diesels if the gasket is applied without the use of Mopar Silicon Rubber Adhesive RTV sealant PN 04883971 This bulletin provides specific routing of the sealant when replacing the engine oil pan gasket When replacing an oil pan gasket apply a 1 8 bead of RTV to the oil pan side of the gasket around the back of the engine extending up to the fourth bolt hole from the
138. gh August 20 2007 The on board diagnostic OBD system on about 74 000 of the above vehicles may not detect a failed oxygen sensor or illuminate the malfunction indicator light MIL as required In addition the OBD system may cause these trucks to fail an inspection maintenance test and may not store mileage as required for certain transmission faults Repair The oxygen sensor module must be replaced and the engine control module ECM must be reprogrammed flashed The new software will also improve vehicle drivability and reduce the potential for exhaust soot accumulation in the vehicle s particulate filter The recalibration of the ECM updates and supersedes TSB 18 033 07 Revision B dated 6 28 07 see page 63 for details EMISSIONS RECALL H31 VECI LABEL Date October 2008 Models 08 D1 Dodge Ram 3500 Truck Cab and Chassis An incorrect Vehicle Emission Control Information VECI label was inadvertently installed on about 60 of the above vehicles The original VECI label does not include the required information for vehicles built without a pickup box Repair Anew VECI label must be installed over the vehicle s original VECI label SAFETY RECALL H34 DASH SILENCER PAD Date January 2009 Models 07 08 DH D1 DC DM The dash silencer pad on about 110 000 vehicles built with a Cummins 6 7 liter diesel engine through 11 5 07 may sag and contact the exhaust gas recirculation EGR cooler This may cau
139. gine identified by a C in the eighth position of the VIN The throttle control cable on your Ram truck may fray and eventually break A frayed throttle control cable may not allow the throttle to return to the idle position In addition the throttle control linkage joints may corrode and cause the throttle to bind or stick Either of the above conditions could increase the truck s stopping distance and cause an accident without warning DaimlerChrysler will repair your truck free of charge parts and labor To do this your dealer will replace your truck s throttle control cable and throttle linkage The work will take about 1 0 hour to complete The service repair procedure involves removal of the throttle control cable throttle linkage rod ends and linkage ball studs as all of these parts are replaced Detailed removal and reinstallation instructions are provided to the dealership reference Safety Recall 970 94 If you have already experienced the problem described above and have paid to have it repaired you may send your original receipts and or other adequate proof of payment to the following address for reimbursement DaimlerChrysler Customer Assistance Center PO Box 1040 St Charles MO 63302 1040 Attention Recall Center UPPER CONTROL ARM FASTENERS Recall 955 2001 BR BE Ram Truck Quad Cab manufactured in July 2000 The upper control arms attached with cadmium coated nuts can cause the bolts to stret
140. he revised propeller shaft SUBJECT DESCRIPTION Shudder when pulling away from stop when operated at maximum GVW rating The bulletin is a supersession of bulletin 16 01 94 If the vehicle exhibits a driveline shudder while pulling away from a stop at maximum GVW rating the bulletin describes the replacement of the two piece driveline and center support bracket with a single piece assembly Droaning noise vibration The symptom typically occurs at maximum load and is engine speed specific 1900 rpm for 4x2 models 1850 rpm for 4x4 models with the truck in fourth gear and the torque converter clutch locked up If the problem is identified a repair procedure involving a revised propeller shaft with a yoke weight damper is described A Publication of the TURBO DIESEL REGISTER CATEGORY 5 BRAKES TSB MODELS 05 14 95 A 95 96 BR 2 9 96 05 02 96 A 94 97 BR 11 15 96 2500 8800 GVW sales code and 3500 built before 8 5 96 05 08 96 94 96 BR 9 13 96 05 09 96 All 10 4 96 05 10 96 94 97 BR 12 13 96 CATEGORY 8 SUBJECT DESCRIPTION Brake pedal noise when depressed The symptom is a squawk type noise when the brakes are depressed The repair involves installing a revised back up plate into the brake combination valve Accelerated brake lining wear front versus rear The bulletin supersedes TSB 05 02 96 dated 2 23 96 The bulletin adds the 3500 series truck and incorporates the use of
141. how to obtain the radio s anti theft code This bulletin also supersedes bulletin 08 051 11 dated 8 20 11 by providing updated service information Editor s Comments Radios Have you tried to restore a car with a coded radio I ve been playing with BMW coded radios from cars that are now 25 years old What a pain in the tail This brings several questions to mind In today s market where a replacement can be purchased for 69 does theft occur that often Why is Chrysler 30 years behind the theft code thing What implications will this have to Joe second owner Joe restoration who does not have TSB 08 011 12 to tell him how the dealer can unlock a code Geez CATEGORY 9 ENGINE 09 004 11 Any Cummins diesel 9 12 11 engine that is still covered under the provisions of the factory warranty A Publication of the TURBO DIESEL REGISTER Dust out diagnosis for Cummins diesel engines This information only bulletin involves proper inspection procedures to determine engine failure due to dust out condition Engines damaged due to the infiltration of dirt and or debris through the air intake system are not warrantable Engines that exhibit particular symptoms that may have been caused by improper air filtration and or lack of proper maintenance Some of these symptoms are listed below not limited to Knocking Hard or no start Low power poor performance Oil consumption Lower end bearing failure Broken rod Smokin
142. ible if the oil check is performed on a warm engine due to slow drain back from the inline fuel pump Discuss with customer and assure dipstick is updated to part number 4796874 The correct dipstick increases the safe zone to two quarts versus the early 94 vintage dipsticks with only a one quart safe zone Excessive oil drainage from oil draft breather tube The bulletin applies only to engines built prior to 12 1 94 It involves replacing the tappet cover with a new sealed version Cummins exhaust manifold gaskets Service gaskets and production gaskets can vary in thickness Do not intermix If an exhaust gasket requires replacement then replace all six Service manual revision for Cummins piston grading procedure The information only bulletin details the pistons to be used if engine rebuild is necessary Cylinder head bolt torque tightening procedure The information only bulletin describes the bolt tightening procedure for cylinder head bolts Knocking noise at rear of engine due to a cracked torque converter drive plate On trucks built prior to 2 8 89 if there exist a knocking or grinding noise at the rear of the engine check the torque converter drive plate for cracking Replace as necessary CATEGORY 11 EXHAUST TSB MODELS 11 03 94 94 BR 5 13 94 11 02 92 88 92 AD 7 27 92 CATEGORY 14 SUBJECT DESCRIPTION Diesel exhaust stains The bulletin applies to 5 speed trucks built prior to 2 1 94 and a
143. ilable on the engine data plate which is located on the left side of the engine affixed to the gear housing The customer may experience a quick momentary stumble while driving or when stopped with t he engine running This condition is intermittent and may occur at any time during the operation of the vehicle A change to the Cummins CM551 Engine Control Module ECM software corrects this condition calibration change 99CalT9A STEERING TSB 19 03 99 05 07 99 19 04 99 05 28 99 CATEGORY 21 MODELS 94 99 BR 99 BR SUBJECT DESCRIPTION Steering slow to return to center This bulletin supersedes technical service bulletin 19 01 94 dated January 28 1994 This bulletin applies to 4x4 vehicles equipped with a Dana model 60 front axle sales code DRD The rate of steering return to center after turning a corner may be slower than normal or may require slight steering wheel correction while driving straight ahead The repair involves performing a ball joint tightening sequence Steering system diagnosis Customers may complain that the steering system feels heavy or the steering wheel is not centered while driving on a straight road The steering gear used on the 1999 Ram Truck is designed to have a heavy on center steering characteristic Before replacing a steering gear for a steering system feel complaint perform the suggested diagnosis to ensure that the rest of the steering system components perf
144. increase the Urea in the DEF degrades As the concentration degrades the urea will become less effective at reducing NOx levels in the SCR catalyst The following chart provides the approximate shelf life of DEF Versus temperature Temperature Estimated Useful Life 32 F 0 C Indefinite 50 F 10 C 75 Years 68 F 20 C 11 Years 86 F 30 C 23 Months 95 F 35 C 10 Months 104 F 40 C 4 Months 122 F 50 C 1 Month 140 F 60 C 1 Week A Publication of the TURBO DIESEL REGISTER 19 TSBs Issued During 2011 CATEGORY 7 COOLING TSB MODEL SUBJECT DESCRIPTION 07 003 10 07 10 DC DM High coolant temperatures on vehicles equipped with snow plows 9 9 10 11 DD DP Customers that operate their vehicle with a snow plow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence e Turn the ignition key to the run position or start the truck e Simultaneously press and release the Cruise Control Cancel button lever and the Exhaust Brake button Repeat this sequence four times within five seconds The chime will sound twice as an audible indicator that the function is engaged e To disable the function repeat the
145. ission CATEGORY 7 The bulletin describes a powertrain induced cyclic noise condition that appears to be transmission driveline related Especially noticeable in 4th and 5th gears the noise occurs below 1400 rpm during coast or light throttle The noise is not damaging or durability related The diagnosis involves a road test to pinpoint the rpm at which the noise occurs The revision involves a change of the flywheel COOLING TSB MODELS 07 04 94 94 BR 4 8 94 07 07 94 94 95 BR 9 30 94 07 01 91 89 90 AD 1 28 91 07 04 91 90 91 AD 9 23 91 07 05 91 91 AD 12 16 91 07 03 90 All 12 21 90 07 01 89 88 89 with 2 27 89 automatic transmission CATEGORY 8 SUBJECT DESCRIPTION Service manual revision thermostat seals Revised service manual pages showing t stat seal pictures Engine slow to warm up in cold ambient temperatures The bulletin describes an overcooling condition caused by the thermostat being stuck in a partial open position Gauge fluction is addressed and is considered normal with no action required Owners are advised that the cooling system is large to provide capacity and protection for high temperatures and high GCWR ratings Slower warm ups are to be expected Overheating or no heat condition An interference between the thermostat and cylinder head coolant passage on engines built before engine serial number 44465181 may result in a stuck t stat in the open o
146. ituations the customer may describe the condition as a lack of a transmission shift TCC lock up between 30 to 50 MPH The transmission valve body upper housing separator plate was revised with a wider 0 470 inches slot in the lockup vent circuit to improve fluid flow in the torque converter clutch This bulletin involves the replacement of the transmission valve body upper housing separator plate Tapping knocking sound during idle This bulletin applies to vehicles built before May 10 2000 equipped with an automatic transmission A tapping knocking sound may be heard or felt in the driver side floor pan area during idle conditions With the engine running at an idle listen for knocking sound coming form the driver side floor pan area If a tapping knocking sound can be heard replace the shift linkage with revised parts BODY TSB MODELS 23 03 00 00 BR 02 04 00 23 19 00 94 01 BR 05 05 00 23 25 00 97 01 BR 06 30 00 SUBJECT DESCRIPTION Vehicle Identification Number VIN Plate Relocated The VIN plate on the subject model vehicles has been relocated from the instrument panel to the cowl bar Due to the relocation of the VIN plate the windshield frit the frit is the black out band at the bottom of the windshield required a change so that the VIN plate could be seen through the windshield The view of the VIN plate may be blocked if a 1999 or earlier windshield is installed on the vehicle
147. l WIF alert To improve awareness that water has been detected in the fuel system the vehicle operator will be alerted to a five 5 chime alert versus a single 1 chime alert This bulletin involves selectively erasing and reprogramming the powertrain control module PCM with bootloader software and application software CATEGORY 18 VEHICLE PERFORMANCE continued 18 030 07 04 26 07 18 033 07 Rev B 06 28 07 64 04 07 DR DH D1 DC 07 DH D1 Engine off idle speed limit feature to protect turbocharger when vehicle is not moving This bulletin applies to vehicles equipped with a 5 9 liter or a 6 7 liter Cummins Turbo Diesel engine sales codes ETC ETH or ETJ This bulletin involves a discussion regarding an engine control feature that limits engine off idle speeds when the vehicle is not moving Dependent upon engine coolant temperature the engine control module ECM will temporarily limit the maximum engine speed when the vehicle is not moving For automatic transmission equipped vehicles the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph and when the transmission selector is in either the neutral or park position For manual transmission equipped vehicles the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph This ECM feature is used to protect the engine turbocharger This delay in maximum engine and turbocharger shaft s
148. ld weather environments This bulletin applies to all Ram trucks equipped with a 5 9L 24 valve Cummins diesel engine with a 49 state emissions calibration and an automatic transmission The bulletin describes how to selectively erase and reprogram the Powertrain Control Module PCM with new software 59t7a The problem addressed by the PCM reprogram is a hard starting and or idle speed fluctuations condition Cummins 24 valve engines used with automatic transmissions can be severely affected by the use of sub grade 1 diesel fuel when ambient temperatures are below 0 C 32 F typically prevalent during the Winter months in Alaska Northwestern Canada and similar climates temperatures elsewhere This change will have no effect on performance during warm weather or when standard grade diesel fuels 1 or 2 are used Vehicles with 49 state certification can apply this calibration change if needed The calibration can be changed back to the original calibration if desired A Publication of the TURBO DIESEL REGISTER CATEGORY 19 STEERING TSB MODELS 19 009 01 97 02 BE BR 10 26 01 CATEGORY 21 SUBJECT DESCRIPTION Driver airbag trim cover service Driver airbag trim covers horn switches for the above vehicles are serviceable and as such when applicable must be used instead of replacing the airbag module assembly Airbag module assemblies returned for trim cover and serviceable horn switch issues are subject to cha
149. lding Hot melt glue clear to light brown can seep out at the edge of the light or molding The repair is to clean the glue with Mopar Concentrated Windshield Washer Solvent Tailgate latch handle loose The bulletin applies to vehicles built from 8 30 94 to 9 8 94 The hole in the tailgate was stamped oversize Inspect the latch handle and apply Mopar Bond All Gel Adhesive to correct Cup holder rattle If cup holder rattles in the closed position add a foam block to the back of the mug holder Front seat cover wear through above the recliner pivot The condition is wear through at the recliner pivot Inspect as directed and repair if necessary Tailgate hard to latch in cold temperatures If the tailgate is difficult to latch when ambient temperatures are below freezing the strikers should be checked for proper adjustment If the problem persist replace the caliper stop with a shorter one part number 55075773 13 CATEGORY 23 BODY continued 23 101 94 94 95 BR 12 30 94 23 57 93 94 BR 10 8 93 23 64 93 94 BR 11 19 93 23 21 92 93 AD 9 8 92 23 09 91 92 AD 8 26 91 23 12 90 91 AD 10 8 90 23 24 89 90 AD 10 10 89 23 08 89 89 AD 4 10 89 CATEGORY 24 Anti friction tape on A pillar Bulletin 23 36 94 described a squeak and paint abrasion at the door to windshield A pillar area Anti friction tape is now being applied at the assembly plants to prevent the problem Do
150. le for Cummins diesel equipped vehicles is listed below 5 9 Liter Changes Air Filter 5 9 upgraded air filter This filter is similar in design to the current 6 7 liter air filter The part number is 53034249AA Element Air Filter 2003 2007 5 9 liter 6 7 Liter Changes Fuel Filter New fuel filter This is the FS2 design 5 and 10 micron filter in filter fuel filter to retrofit earlier models shell and element 68061633AA FS2 Element fuel filter and shell 68061634AA FS2 Element fuel filter This filter to supersede the original 5183410AA filter when supplies are exhausted 6 7 Liter and 5 9 Liter Changes Tank Ventilation Fuel tank vent hose 5 9 and 6 7 add on or upgraded fuel tank vent hose kit with vent cap 68068997AA Fuel Tank Vent 66 10 Must be used in conjunction with the appropriate Fuel Tank Vent Kit listed below 68051906AA Kit Severe Duty Fuel Tank Ventilation DC 52 Gallon Tank 32 95 68061341AA Kit Severe Duty Fuel Tank Ventilation D1 DH 35 Gallon Tank 58 85 68061342AA Kit Severe Duty Fuel Tank Ventilation D1 DH 34 Gallon Tank 63 20 6 7 Liter and 5 9 Liter Auxiliary Fuel Filter Severe duty fuel filter kit This kit supplies the owner with an auxiliary fuel filter mounting bracket for under the frame installaiton hoses hardware and electrical connections to add annother fuel filter to the truck 68083851AA kit 07 12 Cab and Chassis 68083853AA kit
151. le linkage adjustment and air bleed procedures Any other adjustments or modifications are considered tampering Tampered injection pumps are not warrantable The bulletin shows the service location where to look for suspected tampering A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS 18 25 97 96 97 BR 8 15 97 18 29 97A 96 98 BR 12 5 97 with Cummins engine and five speed transmission SUBJECT DESCRIPTION EGR system failure with Hex Code 2E on 5 9L Diesel This bulletin applies to vehicles equipped with a 5 9L Cummins Diesel engine built between Jan 1 1996 and Dec 31 1996 with California emissions sales code NAE If while performing other diagnostics the technician notices Hex Code 2E EGR SYSTEM FAILURE on the Diagnostic Scan Tool DRB III the diagnosis outlined in the bulletin should be followed The customer may or may not experience any engine driveability symptoms The Malfunction Indicator Lamp MIL will not be illuminated The repair involves using revised test procedures to diagnose the EGR system and selectively erase and reprogram the Powertrain Control Module PCM with new software calibration changes for the condition listed Editor s note 2E is correct Vehicle bucking on 96 thru 98 trucks with the Cummins engine and a manual transmission This bulletin supersedes TSB 18 29 97 dated 10 17 97 The condition to be corrected is one where th
152. ling shems between the wheel and 2500 hub bearing assemble 3500 hub extension as required 05 02 95 94 95 BR Front brake noise on trucks with 86 mm diameter caliper pistons 3 24 95 3500 4x4 4x2 The symptom is a squeal noise when applying the brakes for a normal stop The repair involves 2500 4x4 grinding or filing a chamfer on both ends of the front brake pads 05 03 94 94 BR Service manual revision for brake bleeding procedure on trucks equipped with ABS brakes 3 4 94 05 21 94 89 93 AD Premature brake wear on trucks with 12 brake drums 10 21 94 The bulletin involves replacement of the rear brake shoes linings with revised shoes 05 08 93 A 94 BR Pedal feel characteristics of ABS brakes is the subject of this information only bulletin 9 3 93 05 15 93 94 BR Brake pedal noise 11 1 93 The symptom is a squawk caused by the metering valve spring chattering when the brake is depressed The bulletin involves the installation of a revised metering valve 05 04 92 A 89 92 AD Premature brake wear on trucks with 12 brake drums 4 21 92 sales code BKH BKJ The bulletin involves replacement of the rear brake shoes lining with revised shoes 05 01 91 81 91 AD Rear wheel anti lock speed sensor connector repair procedure 1 28 91 If a red amber ANTILOCK warning light illuminates and a code 9 diagnostic code is found a possible cause is the connector for the RWAL speed sensor The
153. luminated even after the parking brake pedal has been released The parking brake system however is not mis adjusted and functions normally Install new parking brake cables ELECTRICAL TSB MODELS 08 010 01 94 02 5 25 01 08 016 01 02 BR BE 8 3 01 08 017 01 02 BR BE 9 21 01 08 025 01 94 01 BR BE 11 23 01 SUBJECT DESCRIPTION Airbag clock spring service When servicing any airbag system it is essential to follow the proper Service Manual and or Diagnostic Manual procedures for diagnosing testing and replacing of any component Do not use silicone or any other lubricant spray on or near the clock spring Lubricants are often used in the clock spring area of the steering column to eliminate noise Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered This includes clock spring replacement steering column service HVAC service steering gear service and front suspension crossmember service Locking radio antenna connector This information only bulletin applies to all 2002 vehicles equipped with radios The radio units will have a new locking radio antenna connector This connector requires that a sliding plastic collar be pulled away from the radio similar to an air hose connector to release the lock Pulling the antenna out of the radio without activating the release could damage the antenna or the radio
154. ly 02 06 90A 90 91 AD 2WD 12 17 90 vehicles only 02 09 90 89 90 AD 4WD 11 19 90 CATEGORY 3 SUBJECT DESCRIPTION Rattling clunk type noise from front of vehicle Verify that the stabilizer bar is built with the correct ball stud links If necessary the bulletin details the replacement of both stabilizer links with tapered ball stud links Service manual revisions for torque values on front suspension This information bulletin differentiates the track bar used on different vintage trucks Low ride height on 8800 GVW cab chassis The bulletin describes abnormal low ride height in the rear where the truck is loaded near GVW It lists the parts necessary to replace the shocks and rear leaf springs Service manual revision for torque values on stabilizer link bar Front spring spacer for two wheel drive trucks The condition is a vehicle leaning or low on the left front corner The repair involves the installation of a spacer 4322629 on the left coil spring to raise the left front corner approximately one inch Front spring spacer for two wheel drive trucks The condition is a vehicle leaning or low on the left front corner The repair involves the installation of a spacer 4322629 on the left coil spring to raise the left front corner approximately one inch Service manual revision for camber specification REAR AXLE TSB MODELS 03 03 95 94 95 BR 5 5 95 03 02 93 92 93 AD 5 7 93
155. ly erasing and reprogramming the PCM Cummins with new software Flash 5 9L Turbo Diesel engine system enhancements This bulletin applies to vehicles equipped with a 5 9L Turbo Diesel engine sales codes ETC and ETH respectively The bulletin supersedes 18 022 06 dated 07 13 06 The following enhancements are included with this software update Improved engine cooling radiator fan activation and prevention of possible engine overheat When coolant temperature faults are present the radiator fan is enabled turned on during vehicle operation e Correction to oil pressure reading when engine is operating at higher engine temperatures above 195 F A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE continued 18 038 06 07 DC 12 05 06 18 001 07 06 07 DH D1 01 06 07 18 009 07 07 DC Rev B 07 13 07 A Publication of the TURBO DIESEL REGISTER e Improvement to the Temperature Sensor Rationality Test to prevent possible false test failures and their following related diagnostic trouble codes DTC P0071 Inlet Air Temperature Sensor Rationality DTC P0111 Intake Air Temperature IAT Sensor Rationality DTC P0514 Battery Temperature Sensor Rationality e Additional water in fuel WIF warning added to indicate that the operator has had a WIF DTC P2269 and has continued to operate the vehicle in excess of 500 miles without draining the water from the fuel filter The following
156. mber 23 2000 and the PCM software level is earlier lower than calibration 14 for model year 2001 Quality analysis has determined that insufficient lubrication of certain internal transmission components may occur when a vehicle is operated in temperatures lower than 20 C 5 F This condition may be caused by the automatic transmission fluid ATF freezing in the cooler lines and interrupting the flow of lubricating oil ATF to the transmission overdrive unit This condition should be a concern only in areas where very cold ambient temperatures of 20 C 5 F are experienced The revised software will not allow 4 gear overdrive to occur if ambient temperatures are less than 20 C 5 F The revised PCM software has been implemented to improve transmission reliability The customer should be informed that reduced fuel economy would be expected when overdrive is not in use The repair involves selectively erasing and reprogramming the Powertrain Control Module PCM with new software calibration level 01Cal14 CATEGORY 25 TSB MODELS 25 001 01 01 BR BE 1 19 01 25 002 01 01 BR BE 1 19 01 A Publication of the TURBO DIESEL REGISTER EMISSIONS SUBJECT DESCRIPTION Generic Scan Tool May Not Display Certain DTC s and Erroneous LDP Switch This bulletin applies to vehicles with an RE automatic transmission built before January 12 2001 MDH 0112XX A generic scan tool may not display certain Diagnostic Trou
157. mly lit when in backup camera mode if equipped e Screen fonts too small or unclear e Video playback display too bright e Audio playback sound quality frequency response could be improved e Hands free call information does not display caller ID e Bluetooth streaming audio information is incomplete The repair involves upgrading the software on the RBZ radio Radio software enhancements This bulletin applies to vehicles built with a radio navigation units with sales codes RER REW or REP The problems experienced The radio may lock up when a U Connect call ends this may cause battery drain e Intermittent no sound from audio system e Repeated Updating Channels message when in satellite radio mode e Losing Bluetooth connection intermittently and not displaying accurate caller ID information when using U Connect This bulletin involves upgrading the software on the RER REW or REP Radio Exterior mirror courtesy lamps stay on longer than the customer desires This bulletin involves checking the software version and if necessary flash reprogramming front door control modules with new software This bulletin supersedes bulletin 08 003 11 revision A This bulletin applies to vehicles equipped with exterior mirror courtesy lights sales code LEC built between January 1 2010 and December 13 2010 Static squeal no sound or intermittent sound from speakers This bulletin applies to DJ and D2 vehicles built between July 15
158. moved and are addressed in Recall K01 dated May 2010 The instructions in the bulletin tell the technician how to selectively erase and reprogram the Engine Control Module ECM with new software Engine systems and exhaust aftertreatment systems enhancements Cab chassis trucks equipped with a 6 7 liter Cummins engine have a number of software improvements available This latest service bulletin which supersedes 18 038 06 and 18 001 09 will include improvements to prevent erroneous Malfunction Indicator Lamp MIL illumination e POOOF Fuel System Over Pressure Relief Valve Activated e P0087 Fuel Rail Pressure Too Low e P0106 Manifold Absolute Pressure Sensor Performance e P0191 Fuel Rail Pressure Sensor circuit Performance e P1011 Fuel Pump Delivery Pressure Too Low e P2299 Brake Pedal Position Accelerator Pedal Position Incompatible e P2262 Turbocharger Boost Pressure Not Detected Mechanical The bulletin involves selectively erasing and reprogramming the ECM 1 CATEGORY 19 FRONT SUSPENSION TSB MODEL 19 002 10 08 09 DM 1 23 10 19 004 10 09 DH 5 29 10 SUBJECT DESCRIPTION Steering wander While traveling on a straight stretch of highway a customer may feel the need to provide steering input to correct a vehicle wander condition This bulletin applies to 4x2 vehicles built before August 8 2009 This bulletin involves inspection or replacement of suspension components
159. mper wire from the battery negative to the frame bumper bracket be added if electrical accessories winch lights snow plow etc are added to the vehicle CATEGORY 8 ELECTRICAL continued 08 22 95 5 12 95 08 16 95 A 08 05 94 1 20 94 08 06 94 2 4 94 08 08 94A 5 20 94 08 10 94 2 18 94 08 17 94 4 1194 08 29 94 6 24 94 08 33 94 7 15 94 08 41 94 8 5 94 08 64 94 11 4 94 08 65 94 11 4 94 08 05 93 2 8 93 08 07 93 A 3 19 93 08 45 93 10 8 93 94 96 BR 89 93 AD 94 96 BR 89 93 AD 94 BR 94 BR 94 BR 94 BR 94 BR 94 BR 91 93 AD 94 95 BR 94 95 BR 94 BR 93 AD 92 93 AD with four wheel drive 94 BR Installation of radio equipment The bulletin supersedes 08 31 94 7 15 94 and discusses the proper installation of communication equipment in Chrysler vehicles Speed control over undershoot during set of speed selection The bulletin discusses the adaptive strategy that compensates for vehicle to vehicle variations in speed control cable lengths Pressing the set button without pressure on the accelerator pedal can cause speed fluctuations Proper review of the condition with vehicle operator is recommended Poor AM radio reception Tighten the antenna base to 70 in Ibs to assure reception Infinity radio code RAY looses soun
160. ne oil Some Turbo Diesel trucks were produced without a check valve on the vacuum pump Without a check valve oil may enter the vacuum system A visual inspection of the HVAC system is presented and the repair procedure outlined YOU MIGHT BE A FORD CHEVY OWNER IF Your wife has You ve ever hi 1 2 3 4 5 6 T 8 9 10 Your hood orn From You Might Be A You write off a radiator as a business expense Your truck is insured by Smith amp Wesson There is a puddle in your driveway year round Your stereo speakers used to belong to the Moonlight Drive in Theater ever said Come move this transmission so I can take a bath You read the Auto Trader with a highlight pen t a deer with your truck deliberately There are more than four hats in the rear window of your truck Directions to your house include turn off the paved road ament used to be a bowling trophy Redneck If by Jeff Foxworthy Foxworthy s Southern humor can be found at bookstores everywhere Buy his books for some serious fun A Publication of the TURBO DIESEL REGISTER TSBs Issued During 1997 CATEGORY 24 AIR CONDITIONING TSB MODELS SUBJECT DESCRIPTION 02 03 97A 94 97 BR Rear of vehicle sits too low 8 29 97 This bulletin supersedes TSB 02 03 97 as there were part number errors in the previous bulletin The bulletin applies to 1500 series trucks rated at 6400 GVW and 2500 series tr
161. ngs includes a slightly greater amount of grease than is required for the bearing lifetime lubricant A portion of the grease purges through the self venting seal in the initial few thousand miles to form an additional barrier in the area of the seal and the stamped slinger This barrier aids in the prevention of contaminants passing through the seal and into the bearing Do not remove or clean the purged grease as part of normal maintenance because it provides additional protection and once removed damage to the seal and bearing could result Squeaking noise from rear leaf springs This bulletin supersedes TSB 02 03 96 dated may 31 1996 If the diagnosed condition is a squeaking noise coming from the rear of the vehicle the bulletin gives the correct repair procedure to replace the leaf spring tip liners install spring clip isolators BRAKES TSB MODELS 05 04 99 98 99 BR 05 28 99 05 11 99 94 96 BR 12 31 99 SUBJECT DESCRIPTION Chassis dynamics diagnosis This 21 page bulletin involves diagnosis and repair of a vehicle drift condition and on some vehicles installing a shim between the wheel and the brake rotor between the wheel and hub bearing assembly or between the wheel and hub extension Chassis dynamics diagnosis is the diagnosis of a condition where the vehicle may move either to the right or the left when not controlled by the driver This condition can be caused by any of the following Non f
162. nostics available for DTC P0251 This bulletin applies to vehicles equipped with a 5 9 liter Cummins Turbo Diesel engine Should the engine surge at idle or MIL illumination of code P0251 occur follow the diagnostics in the service bulletin The bulletin involves replacing the FCA with a revised Mopar part number 05183245AA Heavy duty filtration Mopar retrofit or add on parts available This bulletin applies to D1 DH DR vehicles equipped with a 5 9 liter Cummins engine built from 2003 model year and D1 DH DC vehicles equipped with a 6 7 liter Cummins engine built from 2007 model year Several fuel system add on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions The description of parts available for Cummins diesel equipped vehicles is listed below 6 7 Liter Changes e New fuel filter This is the FS2 design 5 and 10 micron filter in filter fuel filter to retrofit earlier models shell and element 68061633AA FS2 Element fuel filter and shell 68061634AA FS2 Element fuel filter This filter to supersede the original 5183410AA filter when supplies are exhausted 6 7 Liter and 5 9 Liter Changes e Fuel tank vent hose 5 9 and 6 7 add on or upgraded fuel tank vent hose kit with vent cap 68068997AA Fuel Tank Vent Must be used in conjunction with the appropriate Fuel Tank Vent Kit listed below 68051906AA Kit Severe Duty Fuel Tank V
163. nterference to from two way radio receivers Customers may complain of intermittent poor reception on their two way radios This bulletin involves installing a RFI filter in series with the electric fuel pump motor Plastic boot to protect the electrical harness B end terminal at the generator While service is being performed to the engine it may be possible for a momentary electrical short to occur The electrical short may be caused when a metallic object such as a wrench or oil filter comes in contact with the B end terminal of the generator wire harness The B end terminal is bolted to the generator B stud output terminal The B stud on the generator is protected by a plastic surround Part of the wire harness end terminal may extend beyond the protective plastic surround for the B output terminal This bulletin applies to vehicles equipped with a 5 9L 24V diesel engine built before engine serial number 56681800 with a date of manufacture of January 29 2000 The repair procedure involves the installation of a protective rubber boot part number 04487042 over the B terminal Central timer module electrically locks up This bulletin applies to vehicles equipped with remote keyless entry sales code GXR In addition this bulletin applies to vehicles built on or before the following build dates Ram trucks built at the St Louis North Assembly Plant on or before August 21 2000 Ram trucks built at the Saltillo Truck Assembl
164. nto its seat Repair of etched paint This bulletin involves evaluating the paint condition on all horizontal panels for etching If the problem exists the bulletin describes the proper repair procedure using sanding buffing techniques or spot paint refinishing HEATING amp A C TSB 24 009 02 10 28 02 24 003 03 5 23 03 14 MODELS 90 04 All Chrysler Group products using R 134A refrigerant 90 04 All Chrysler Group products SUBJECT DESCRIPTION A C system leak detection Vehicles from the factory no longer have leak detection dye in the A C system To determine the source of a R 134a leak a leak tracer dye has to be injected into the A C system A C system additives The use of A C system sealers may result in damage to A C refrigerant recovery evacuation recharging equipment and or A C system components Many federal state provincial and local regulations prohibit the recharge of A C systems with known leaks DaimlerChrysler recom mends the detection of A C system leaks through the use of approved leak detectors available through Pentastar Service Equipment PSE and fluorescent leak detection dyes available through Mopar Parts Vehicles found with A C system sealers should be treated as contami nated and replacement of the entire A C refrigerant system is recommended A Publication of the TURBO DIESEL REGISTER CATEGORY 24 HEATING amp A C continued 24 004 03 03 DR 6 13 03 24 021 05
165. nvestigation by the technician may reveal that the MIL illumination and or EVIC message is due to one or more of the following diagnostic trouble codes DTC s P1451 Diesel Particulate Filter System Performance P242F Diesel Particulate Filter Restriction Ash Accumulation P200C Diesel Particulate Filter Over Temperature Bank 1 This bulletin provides revised diagnostic and repair procedures for DTC s P1451 P200C P242F black smoke from the exhaust or a no start condition due to a nonfunctional or plugged diesel particulate filter DPF Diesel particulate filter Stationary DeSoot This bulletin applies to D1 DH vehicles equipped with a 6 7 liter Cummins diesel engine sales code ETJ Mobile DeSoot still applies to DC DM vehicles equipped with the 6 7 liter Cummins diesel engine sales code ETJ Stationary DeSoot has replaced Mobile DeSoot as the repair for Diagnostic Trouble Codes P1451 and P2463 This bulletin provides the procedure to perform Stationary DeSoot This new procedure allows running the DeSoot in a secured area with the vehicle unattended Stationary DeSoot can only be performed when the diesel particulate filter has exceeded a specified soot threshold The Diagnostic Scan Tool will not allow the procedure to operate unless the threshold has been exceeded If the vehicle does not have an active P1451 the soot in the Diesel Particulate Filter is at a normal level and a scan tool initiated DeSoot is not needed
166. o interference to from two way radio receivers This bulletin addresses the complaint of intermittent poor reception on two way radios and discusses the proper repair Radio receivers from approximately 30 MHZ to 50 MHZ may be susceptible to Radio Frequency Interference RFI from the Airbag Control Module ACM Note technical service bulletin 08 06 99 dated March 5 1999 addresses two way radio interference from the fuel pump module and should be performed prior to performing this technical service bulletin Airbag On Off Switches This bulletin supersedes technical service bulletin 08 17 98 Rev C dated December 30 1998 This information only bulletin identifies the parts and procedures necessary to deactivate airbags authorized by NHTSA Airbag deactivation is a customer pay procedure NOT covered under the provisions of the warranty Communications may stop between the JTEC PCM and a generic scan tool This information applies to vehicles built before November 30 1999 The JTEC Powertrain Control Module PCM may stop communications with a generic scan tool This bulletin involves selectively erasing and reprogramming the JTEC PCM with new software calibration change 00Cal13 amp 00Cal13A 31 CATEGORY 8 ELECTRICAL continued 08 42 99 98 99 BR 12 17 99 08 43 99 98 99 BR 12 17 99 08 44 99 99 00 BR 12 31 99 The fuel gauge reads full for an excessive period of time This bulletin appli
167. o prevent unnecessary malfunction indicator lamp MIL illumination for P061A ETC Level 2 Torque Performance P20EE ACR NOx Catalyst Efficiency Below Threshold Bank 1 P229F Aftertreatment NOx Sensor Circuit Performance Bank 1 Sensor 2 P2609 Intake Air Heater System Performance P1123 Power Take Off System Monitor Control Error U010E Lost Communication With Diesel Exhaust Fluid Control Unit Enhanced Diagnostics For Selective Catalyst Reduction SCR efficiency diagnostic improvements Other Update Idle shutdown message on EVIC Turbo protection feature Not displayed if vehicle is in park or no vehicle speed Limits RPM at cold ambient to prevent turbo damage Scan tool display updates Correct operation of remote PTO System robustness improvements The bulletin involves selectively erasing and reprogramming the engine control module ECM with new software 18 013 12 12 DJ D2 Diagnostic and system improvements 3 17 12 This bulletin supersedes service bulletin 18 055 11 dated December 17 2011 This bulletin involves selectively erasing and reprogramming the engine control module ECM with new software The software package has improvements enhancements available for the following DTC s P049D EGR Control Position Exceeded Learning Limit P2002 Diesel Particulate Filter Efficiency Below Threshold P2195 02 Sensor 1 1 Out of Range High P2196 02 Sensor 1 1 Out of Range Low
168. obble More often than not the customer wants a one size fits all answer to the problem It is not that easy and the Geno s staff suggests that they save money by crawling under the truck to diagnose the problem So it is refreshing to see that Dodge has helped us tackle the problem with a step by step repair procedure The TDR has also covered the death wobble problem and in Issue 74 pages 12 23 we presented Steering Woes If you are having death wobble problems this article is well worth your reread Finally there is a part not mentioned in the Dodge TSB that can be added to your truck to help stabilize the front end My guess as to why Dodge didn t mention a steering box stabilizer is that it is an aftermarket item not offered through the Mopar parts system CATEGORY 21 TRANSMISSION AND TRANSFER CASE TSB MODEL SUBJECT DESCRIPTION 21 011 11 11 DD DP Difficulty climbing steep grades at maximum gross combined weight rating in third and fourth 11 4 11 gear This bulletin applies to Cab and Chassis vehicles equipped with a six speed Aisin automatic transmission Customers may notice they have difficulty climbing steep grades at maximum gross combined weight rating while the vehicle is in third and fourth gear This usually happens while towing a trailer This could also be described as a lug down feeling in third and fourth gear A new feature has been added to the TCM logic that allows new downshift points for the 4 3 an
169. on two cargo box cross member rails Upper rear corner of front door contacts upper front corner of cargo door This bulletin applies to Quad Cab Ram trucks and describes a door closing condition where the upper rear corner of the front door may come in contact with the upper front corner of the cargo door causing the paint to chip off the front and or cargo door If such the correction is the installation of an anti chip plastic molding over the chipped area Water leaking into vehicle through side cowl panel This bulletin applies to vehicles built between November 16 1997 and November 26 1997 If water leaks through either the right and or left side cowl panels and dampens the carpet in the foot well area a trim cover is removed and a water proof patch is installed over the cowl panel A Publication of the TURBO DIESEL REGISTER CATEGORY 24 AIR CONDITIONING TSB MODELS 24 11 97 94 98 BR 7 11 97 A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION A C evaporator odor This bulletin supersedes technical service bulletin 24 06 95A dated 5 26 95 Some vehicle operators may experience a musty odor from the A C system primarily at start up in hot and humid climates This odor may be the result of microbial growth on the evaporator core During normal A C system operation condensation forms in and around the A C evaporator When airborne pollutants mix with this condensation bacteria and fungi growth begins and o
170. or flashed the OBD readiness monitors may need to run again to complete the monitoring process This bulletin describes the necessary steps required to run each monitor Customers may be required to drive the vehicle for an extended period of time in a variety of driving styles to allow all of the OBD monitors to run Diagnostic trouble code DTC P0471 set in temperatures below freezing This bulletin involves installing an insulated exhaust manifold pressure EMP sensor tube and insulation over the EMP sensor along with a new EMP sensor During the normal combustion process condensation can form in the EMP sensor tube Rarely this condensation may contact the EMP sensor pressure sensing element If the vehicle is operating in temperatures below freezing the condensation may freeze The expanding moisture as it freezes could cause the pressure sensing element to crack causing damage to the EMP sensor and setting DTC P0471 will illuminate the MIL immediately after the fault becomes active Diesel exhaust fluid This bulletin provides information regarding the diesel exhaust fluid DEF vehicle delivery fill guidelines The bulletin supersedes 25 001 10 dated 9 1 10 The tank is pre filled with approximately three gallons of DEF from the manufacturing assembly plant This factory fill should be adequate to perform the vehicle s Pre Delivery Inspection and other in dealership operations A Publication of the TURBO DIESEL REGISTER RECALL N
171. or the type of steering linkage the vehicle is equipped with and those found with a certain linkage configuration must have the right and left tie rod angles measured If the tie rod angles are not within specification the left tie rod must be replaced Note special Tool 10326 was released to dealers in November of 2010 Service Bulletin 19 001 11 was also issued to alert dealers to the new service tool and procedure for setting toe on the affected and all subsequent vehicles A Publication of the TURBO DIESEL REGISTER If ve heard it once I ve heard it a hundred times the TDR reads like a storybook and you have to keep the back issues handy or you ll miss a topic that has been previously covered At times know it is frustrating But for the sake of the editor s sanity and page count containment often do the chapter and verse thing The point of this rambling if you have a problem with a late model truck you ll want to review the TSBs in issues 74 70 66 and 62 all of which can be found at our web site Likewise review those magazines for any recall notices that may apply to you Finally did you notice that the TSBs are fewer in number at the end of a vehicle s lifecycle What is an owner to do purchase the end of the old generation on be the first on the block with the new Both scenarios have their benefits Regardless of you choice lII try to keep you up to date with our annual TSB review Robert Patton
172. orm as designed TRANSMISSION TSB 21 08 99 04 30 99 21 14 99 11 05 99 34 MODELS 96 99 BR 00 BR SUBJECT DESCRIPTION Buzz whine or moaning type noise from a cold transmission when reverse is selected Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected This noise has been described as a buzz whining or moaning like noise The noise is most noticeable when transmission fluid temperature is below 100 degrees F 38C The condition is caused by a resonance of the transmission regulator valve system The repair involves replacing the transmission regulator valve 47RE transmission harsh or early shifts This information applies to vehicles equipped with a 5 9L 24V diesel engine and 47RE automatic transmission built before engine serial number 56624822 with a date of manufacture A Publication of the TURBO DIESEL REGISTER CATEGORY 21 TRANSMISSION continued 21 19 99 11 12 99 CATEGORY 23 99 00 BR of August 28 1999 This information is available on the engine data plate which is located on the left side of the engine affixed to the gear housing Some early built 2000 model year Ram Trucks may experience a harsh 3 4 shift This condition may occur during any throttle position situation when transmission sump temperatures are 60 degrees F 15C or higher The harsh 3 4 shift may be more pronounced during heavy vehicle loading e g t
173. ot be disabled 68 A Publication of the TURBO DIESEL REGISTER CATEGORY 21 TRANSMISSION continued 21 006 06 05 06 3 11 06 21 010 06 All 4 14 06 21 003 07 02 09 07 21 006 07 05 DH 03 20 07 21 009 07 04 07 5 24 07 A Publication of the TURBO DIESEL REGISTER Transmission jumps out of reverse This bulletin applies to vehicles equipped with Cummins Turbo Diesel engines sales code ETH and G56 manual transmissions sales code DEG A customer may experience the transmission jumping out of reverse If the customer indicates that the condition is present perform the repair procedure which involves replacing the reverse synchronizer Automatic transmission fluid usage ATF 4 Type MS9602 This bulletin supersedes technical service bulletin 21 004 04 dated March 16 2004 ATF 4 type 9602 is being used as factory fill for Chrysler Group automatic transmissions ATF 4 is recommended for all vehicles equipped with Chrysler Group automatic transmissions except for those noted AW 4 transmissions Sprinter transmissions Crossfire transmissions MK PM vehicles equipped with Continuously Variable Transmission CVT ATF 4 is backward compatible with ATF 3 ATF 2 and ATF Additionally ATF 4 can be used to top off vehicles that used ATF 3 ATF 2 or ATF Benefits e Better anti wear properties e Improved rust corrosion prevention e Controls oxidation e Eliminates deposits e Controls friction e Retains anti fo
174. ound can be heard when the driver s side wiper blade reaches its full upper wipe position farthest to the left during high speed wiper operation this bulletin describes the repair procedure The repair has the dealership replace the wiper blades with a blade that has a revised air deflector Windnoise whistle around grille area This bulletin supersedes TSB 23 27 96 dated 4 19 96 Vehicles may exhibit a condition where a windnoise whistle occurs from the front of the vehicle This condition can occur while driving the vehicle at highway speeds between 45 65 mph or at slower speeds when driving into a headwind If necessary a foam strip is installed between the grille and hood Water leaking through rear window The problem is water leaking past rear window module into cab of vehicle The bulletin outlines the repair procedure Driver side power mirror vibrates while driving This bulletin supersedes TSB 08 64 94 dated 11 4 94 The condition covered in the bulletin is one where the driver side power mirror vibrates causing blurred images in driver side mirror while driving The repair involves installing a power mirror support bracket onto the driver s side mirror Noise coming from cargo box area The problem is an oil canning noise complaint coming from the box area caused by the cargo box cross member contacting the vehicle s frame as the vehicle is operated over a rough surfaced road The repair involves installing isolators
175. out 11 300 of the above vehicles may cause excessive vent pressure levels in the power steering hydraulic brake booster system This may cause the vehicle to have brake lights that remain illuminated for an extended period of time after the brake pedal has been released Brake lights that are slow to turn off could increase the risk of a crash To correct this condition the power steering reservoir cap must be replaced 97 EMISSIONS RECALL K34 REPROGRAM ECM EGR DIAGNOSTIC Date February 8 2011 Models 10 DJ D2 Ram Truck 2500 3500 series pickup This recall applies only to the above vehicles equipped with a Cummins engine built from October 1 2009 through June 24 2010 The Engine Control Module ECM on about 1193 of the above vehicles may have been built with a software error that prevents the EGR cooler bypass valve diagnostic from running after detecting a pending fault disabling deNOx without illuminating the MIL This may cause the vehicle s exhaust emissions to exceed the allowable limit for oxides of nitrogen To correct this condition the Engine Control Module ECM must be reprogrammed flashed CUSTOMER SATISFACTION NOTIFICATION L03 DOOR LATCHES Date March 2011 Models 11 D2 Ram Truck 3500 Series Pick up 41 DD Ram Truck 3500 Series Cab Chassis 41 DJ Ram Truck 2500 Series Pick up 11 DP Ram Truck 4500 5500 Series Cab Chassis This notification applies only to the above vehicles equip
176. oved Under no circumstances is the original part to be reused Special Mopar lock seal should be applied to the threads at reassembly Overdrive unavailable in extreme cold temperatures A Publication of the TURBO DIESEL REGISTER CATEGORY 21 TRANSMISSION continued 21 11 95 7 7195 21 04 94 3 4 94 21 10 94 5 27 94 21 17 94 9 16 94 21 18 94 9 30 94 21 24 94 12 2 94 21 25 94 12 23 94 21 23 93 9 3 93 21 39 93 12 31 93 21 18 92 11 30 92 21 11 91 21 05 90 2 26 90 21 14 90 5 7 90 21 12 89 5 1 89 A Publication of the TURBO DIESEL REGISTER 96 BR trucks with automatic transmission 94 BR with manual transmission NV 4500 HD 94 BR with manual transmission NV 4500 HD 94 BR 93 AD with automatic transmission 94 BR 89 93 AD with automatic trans 94 95 BR with automatic trans 94 94 BR with NP 241 HD transfer case 92 93 AD with automatic transmission 89 93 AD with automatic transmission 92 93 AD with automatic transmission 89 91 AD with A 518 automatic transmission 89 90 AD with manual transmission 90 AD with 518 automatic transmission 89 AD with manual transmission The information only bulletin emphasizes a change to the PCM for 1996 For 96 in ammbient temperatures of 5 F and below the PCM inhibits the transmission from shi
177. ped with power door locks sales code JPB built from July 01 2010 through November 23 2010 The right front door latch right rear door latch and or swing gate latch on about 35 000 of the above vehicles may develop a ratcheting sound while using the power door locks The right front door latch and right rear door latch must be inspected and replaced if necessary SAFETY RECALL L16 LEFT TIE ROD Date March 2012 Models Production 08 09 DH 2500 4x4 08 09 D1 3500 4x4 10 11 DJ 2500 4x4 10 11 D2 3500 4x4 08 10 DC 3500 Cab Chassis 11 DD 3500 Cab Chassis a wwe This recall applies only to the above vehicles built at the Saltillo Assembly Plant G in the 11th VIN Position from February 14 2008 through March 28 2011 Models Service Parts 03 04 DR 2500 3500 4x4 06 08 D1 3500 4x4 07 08 DC 3500 Cab Chassis 05 08 DH 2500 4x4 05 DH 3500 4x4 This recall applies only to the above vehicles that were built between July 12 2002 and February 13 2011 and had the steering linkage replaced with Mopar service parts after February 14 2008 Subject The left tie rod ball stud on about 208 000 of the above vehicles may fracture under certain driving conditions This could cause a loss of directional control and or a crash without warning The same vehicles may also have a loose front track bar bolt This could cause a rattle or banging noise under certain driving conditions Rep
178. peed allows for sufficient oil lubrication to the turbocharger shaft bearings which is important for long term turbocharger durability The maximum engine speed for the 5 9 liter engine is temporarily limited to 1 600 RPM when the above conditions are met The 6 7 liter engine speed is temporarily limited to 1 200 RPM when the above conditions are met The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature For example the delay can be up to 45 seconds at 35 or 7 seconds at 70 Ram truck 2500 and 3500 Excessive soot accumulation in exhaust PCM may not reprogram OBD readiness status and other engine system enhancements This bulletin applies to Ram truck 2500 and 3500 vehicles equipped with 6 7 liter Cummins Turbo Diesel engine sales code ETJ built on or before June 11 2007 This bulletin supersedes technical service bulletin 18 033 07 Rev A dated June 12 2007 The vehicle operator and or technician may experience one or more of the following conditions and or enhancements e The technician may not be able to reprogram flash the PCM with new application software The vehicle may fail an emission inspection maintenance I M test because two or more on aboard diagnostic OBD monitors report that they are not ready for testing This condition may cause the customer vehicle to fail an emissions I M test The following is a list of OBD Monitors that may report as not re
179. ply and further powertrain diagnosis may be required This bulletin involves selectively erasing and reprogramming the Cummins CM551 Engine Control Module ECM with new software calibration changes 98Cal T17 and 99CalT8B There is no change to the JTEC PCM software 5 9L 24V Cummins diesel low power or poor performance diagnostic The vehicle operator may complain of slow acceleration or a lack of power when towing or hauling moderate to heavy loads The condition may be worse at higher altitude Do not proceed with this technical service bulletin until TSB 18 11 99 has been performed This bulletin further describes diagnostic procedures that may be used to assist the technician in the diagnosis of a low power or poor performance complaint 5 9L 24V Cummins diesel low power or poor performance diagnostic The vehicle operator may complain of slow acceleration or a lack of power when towing or hauling moderate to heavy loads The condition may be worse at higher altitude This bulletin involves diagnostic procedures that may be used to assist the technician in the diagnosis of a low power or poor performance complaint The procedures outlined start with confirmation that TSB 18 11 98 turbocharger wastegate actuator repair kit has been performed Additionally the technician should verify that the throttle is opening fully e Perform the complete FUEL TRANSFER PUMP PRESSURE TEST procedure CATEGORY 18 VEHICLE PERFORMANCE continued
180. ppear to be intermittent to the customer Because the harsh downshift may occur below 10mph the customer may believe that they are experiencing a harsh 2 1 downshift Some customers may also experience a harsh 2 3 upshift during normal acceleration This symptom is less common than the harsh coast downshift This bulletin involves selectively erasing and reprogramming the transmission control module TCM with new software Automatic transmission diagnostic tear down procedure This bulletin provides a procedure to determine repair versus replacement of an automatic transmission assembly Follow the proper repair procedure based on the transmission type This procedure is to be used after the transmission has been removed from the vehicle WHEELS amp TIRES CATEGORY 22 TSB MODELS 22 001 05 00 01 BR BE 12 1 05 02 06 DR 70 SUBJECT DESCRIPTION Chrome wheel care This information only bulletin discusses chrome wheel care Chrome wheels should be cleaned regularly with mild soap and water or Mopar Car Wash Concentrate to maintain their luster and prevent corrosion Wash them with the same soap solution as the body of the vehicle Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels Any of the Do Not Use items listed below can damage or stain wheels and wheel trim e Wheel cleaners that contain hydrofluoric acid biflouride compounds sulfuric acid
181. ption can be repaired by replacement of the antenna base and cable assembly White smoke at start up Service changes to the powertrain control module SEBC may cause white smoke at start up The SEBC is programmed to eliminate operation of the air intake heater for the first 25 vehicle starts After service or in predelivery situations there may be vehicles that have not accumulated 25 starts The white smoke condition should be resolved after 25 starts are accumulated Speed control surge The bulletin describes the correct speed control servo and cable match for the powertrain control module Verify compatability of components Replace speedometer drive gear if necessary Radio lock up A Publication of the TURBO DIESEL REGISTER CATEGORY 8 08 47 93 10 15 93 08 58 93 12 10 93 08 67 93 12 31 93 08 05 91 4 22 91 08 10 91 9 9 91 08 11 91 10 7 91 94 BR 91 93 AD 94 BR All trucks 89 91 AD 91 AD CATEGORY 9 TSB 09 10 95 6 2 95 09 04 95 4 14 95 09 06 94 4 22 94 09 22 93 12 31 93 09 07 91 12 2 91 09 11 89 7 3 89 A Publication of the TURBO DIESEL REGISTER MODELS 94 95 BR 94 95 BR 94 BR 94 BR 91 92 AD 89 AD with automatic transmission ELECTRICAL continued The bulletin applies to AM FM Stereo RAL or AM FM stereo cassette RAS radios If the buttons and controls do not fun
182. r closed position A revised t stat and coolant passage diameter check a part of the repair procedure Lower radiator hose leakage Some leakage from the lower radiator hose at the waterpump connection may occur due to a step cast in the water pump nipple The repair involves installing a second hose clamp Fan belt noise chirp The noise is caused by excessive paint in the grooves of the water pump allowing the belt to slip Wire brush and solvent to remove the paint is the repair procedure Recycled engine coolant The use of reconstituted antifreeze coolants is not authorized in the performance of any repair covered under the provisions of warranty Auxiliary oil cooler freeze up At ambient temperatures of 10 F or lower trucks with auxiliary coolers NHB may loose transmission fluid due to a restriction of oil flow A bypass line is the recommended repair ELECTRICAL TSB 08 25 95 6 9 95 08 24 95 9 30 95 A Publication of the TURBO DIESEL REGISTER MODELS 94 95 BR 94 95 BR SUBJECT DESCRIPTION Power mirror vibration associated with installation of bugscreen deflectors The symptom is blurred images in the power mirrors The diagnostic procedure remove the bugscreen If vibration ceases the mirrors are ok Bugscreen deflectors are designed to disrupt airflow which can lead to mirror antenna vibration Accessory frame ground jumper wire The bulletin discusses a frame ground ju
183. r may experience a no engine crank and a no engine start condition Also the remote keyless entry system will not operate This condition may be due to an electrostatic discharge from the ignition key into the wireless control module WCM causing the WCM to electronically lock up This condition is corrected by the replacement of the WCM also known as the Sentry Key Remote Entry Module Voice recognition screen lock up on REN or REZ radio equipped with hands free communications The customer may experience one of the following conditions a A lock up condition of the radio screen when the voice recognition VR button is pressed b When the VR button is pressed the radio display changes to the phone screen and there is a lack of the Ready audio prompt If the above symptom condition is experienced the HFM is replaced This bulletin applies to radios built before 11 6 07 Proper testing tools for oxygen sensor terminals This bulletin describes the use of proper test probes to test the oxygen O2 sensor connector terminals equipped with the new TP2 style sensor The recommended tool for these testing procedures is the Miller Tool 6801 ENGINE TSB 09 002 02 3 11 02 09 008 02 10 21 02 09 004 06 03 31 06 MODELS 98 02 BR 98 02 BR BE 03 06 DR SUBJECT DESCRIPTION Crankcase breather overflow This bulletin applies to 1998 2002 BR Ram trucks equipped with the 24 valve Cummins
184. railer towing Some 2000 M Y vehicles may also experience an early 1 2 or 2 3 shift condition during wide open throttle WOT situations This condition may have an impact on vehicle performance acceleration This condition may occur when transmission sump temperatures are 32 degrees F 0C or higher Changes to the Cummins CM551 engine control module ECM software calibration corrects the above two conditions calibration change 00Cal57T9A 47RE delayed TCC lock up and or MIL P1740 TCC or O D solenoid performance This information applies to vehicles built for the California market NAE equipped with a 5 9L 24V diesel engine and built between March 2 1999 and October 1 1999 The customer may experience a delayed torque converter clutch engagement lock up This condition may illuminate the Malfunction Indicator Lamp MIL due to Diagnostic Trouble Code DTC P1740 TCC or O D Solenoid Performance In some situations the customer may describe the condition as a lack of a transmission shift TCC lock up between 30 and 50 mph The transmission valve body upper housing separator plate was revised wider slot to improve fluid flow to the torque converter clutch This bulletin describes the replacement of the transmission valve body upper housing separator plate BODY TSB 23 08 99 03 05 99 23 18 99 05 21 99 23 22 99 07 02 99 23 28 99 08 13 99 23 35 99 Rev A 10 01 99 A Publication of the TURBO DIESEL REGISTER MODE
185. rcuits The TIPM retries the output on each ignition cycle or request brake or turn signal activation in an attempt to enable the output in case the fault is intermittent The new TIPM software raises the TIPM circuit trigger point from 15 amps to 20 amps DTC s B166C and B1670 These DTC s indicate that a short circuit to battery voltage 12 volts exists in the wiring of one of the trailer electrical harness circuits DTC B2215 Front Control Module TIPM This fault code occurs when the TIPM detects a short to ground or to battery on one of the trailer circuits more than 250 times When B2215 is present with one of the above trailer circuit faults the TIPM will turn off disable the respective faulty trailer circuit or circuits This internal fault does not mean that the TIPM module is defective The TIPM memory can be cleared and this action will turn on a previously disabled trailer circuit If possible the fault in the circuit should be repaired first before clearing the TIPM memory The dealer will need a scan tool to clear the TIPM memory DTC P1277 Starter Control Circuit too Low TIPM The TIPM monitors the output current to the starter solenoid for over current conditions The DTC is set when the output current to starter solenoid exceeds 75 amps On trucks equipped with a diesel engine there may be times in cold climates when it is normal for the starter solenoid current to exceed 75 amps The new TIPM software raises the TI
186. rcuits for the stop and turn indicator The bulletin then describes the reprogramming procedure to reset the lamp out indicator PCM connector corroded sets MIL light This bulletin applies to vehicles equipped with a 5 9 liter diesel engine and an automatic transmission Water may enter the PCM connector causing corrosion of electrical terminals on the PCM This condition can set diagnostic trouble codes and illuminate the MIL light If diagnostic trouble codes are present or other diagnostics lead to PCM connector problems inspect the PCM and the PCM wire harness connector The repair procedure involves replacement of the wiring harness Poor radio sound quality with Infinity speakers This bulletin applies to vehicles equipped with Infinity speakers sales code RCK Radios equipped with Infinity Speakers may exhibit a variety of symptoms due to reversed right front speaker wiring polarity Symptoms include front door or speaker buzz poor sound quality lack of bass The solution involves correcting speaker wiring polarity in the radio connector A Publication of the TURBO DIESEL REGISTER CATEGORY 8 ELECTRICAL continued 08 014 04 3 30 04 08 014 05 2 17 05 08 024 05 5 4 05 08 058 05 10 29 05 08 014 06 3 16 06 08 016 06 Rev A 7 18 06 A Publication of the TURBO DIESEL REGISTER 04 DR 04 05 DR 02 06 DR 05 06 DR 06 DR 06 07 DR Radio intermittent audio
187. ready has the revised parts Injection pump diagnosis procedure A troubleshooting procedure is outlined to help diagnose diesel engine problems PROPELLOR SHAFTS amp U JOINTS TSB MODELS 16 02 95 94 95 BR 11 3 95 automatic transmission trucks 16 01 94 94 95 BR 10 14 94 SUBJECT DESCRIPTION Droaning noise vibration The symptom condition is a droaning type noise and or vibration felt in seat track floor pan or steering column The noise is worst case when pulling a camper or trailer with significant wind drag Peak noise level is 1900 rpm for 4x2 trucks 1850 rpm on 4x4 models with torque converter clutch engaged The repair involves replacement of the propeller shaft Shudder at start on vehicles with two piece driveshafts operated at near maximum GVW The symptom is a driveline shudder when pulling away from a stop As the vehicle is loaded the driveline angle will change In the case of maximum GVW the rear differential may rise above the rear driveshaft center bearing The alignment could cause a shudder in the driveline The repair involves replacement of the driveshaft center support bearing bracket and or driveshaft A Publication of the TURBO DIESEL REGISTER CATEGORY 18 TSB MODELS 18 29 95 A 94 95 BR with 10 16 95 automatic transmission 18 01 94 94 BR with 1 14 94 automatic transmission 18 10 94 A 94 BR 7 29 94 18 05 93 91 93 AD 4 30 93 18 06 92 A
188. rear on each side as per the referenced diagram Crankcase breather overflow This bulletin applies to 98 02 BR Ram trucks equipped with the 24 valve Cummins diesel engine built after March 27 1998 ESN 56443872 Owners of 98 02 trucks equipped with the 24 valve Cummins diesel engine may experience engine oil overflow from the front crankcase breather when the vehicle is operated on an extreme downhill grade 36 5 or 22 slope grade Operation of this type for extended periods of time can cause enough engine oil depletion to damage the engine A kit containing all components necessary to eliminate the oil overflow has been made available The bulletin outlines the repair procedure that relocates the breather from the front of the engine to a new location on the driver s side tappet cover VEHICLE PERFORMANCE TSB 18 31 1 New Release 42 MODELS 98 5 2002 BR BE SUBJECT DESCRIPTION Cold idle engine warming This bulletin involves selectively erasing and reprogramming the Engine Control Module with new software This bulletin applies to all Ram trucks built after December 17 1997 equipped with the 24 valve 5 9L Cummins diesel engine Extended idle operation especially in cold weather can allow varnishes oils to condense on the exhaust valve stems leading to stuck valves and damaged valve train components The repair procedure involves calibration software that will activate when certain parameters are met
189. rge back The horn switch is integral to the driver airbag unit Only DaimlerChrysler trained and authorized dealer service technicians should perform service of this unit Failure to take the proper precautions or to follow the proper procedures could result in accidental incomplete or improper airbag deployment and possible occupant injuries TRANSMISSION TSB MODELS 21 004 01 01 BR 02 16 01 21 009 01 01 BE BR 10 15 01 A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION Overdrive disabled to improve transmission reliability during cold temperature operation This bulletin applies to vehicles equipped with an automatic transmission where the vehicle was built on or between June 26 2000 and December 23 2000 and the PCM software level is earlier lower than calibration 14 for model year 2001 Quality analysis has determined that insufficient lubrication of certain internal transmission components may occur when a vehicle is operated in temperatures lower than 20 C 5 F This condition may be caused by the automatic transmission fluid ATF freezing in the cooler lines and interrupting the flow of lubricating oil ATF to the transmission overdrive unit This condition should be a concern only in areas where very cold ambient temperatures of 20 C 5 F are experienced The revised software will not allow 4 gear overdrive to occur if ambient temperatures are less than 20 C 5 F The revised
190. rging System Output Low Diesel P2509 Powerdown Data Lost Error Diesel This bulletin involves selectively erasing and reprogramming the powertrain control module Cummins PCM with new software Ram truck 3500 Cab and Chassis Excessive soot accumulation in exhaust PCM may not reprogram and other engine system enhancements This bulletin applies to Ram truck 3500 Cab and Chassis vehicles equipped with 6 7 liter Cummins Turbo Diesel engine sales code ETJ This bulletin supersedes technical service bulletin 18 009 07 Rev A dated May 16 2007 The vehicle operator and or technician may experience one or more of the following conditions e The technician may not be able to reprogram flash the PCM with new application software e After extensive idling of the vehicle engine or if an intake air leak is present the vehicle operator may experience a MIL illumination and or an electronic vehicle information center EVIC message alert due to one or more of the following DTC s P1451 Diesel Particulate Filter System Performance P2463 Diesel Particulate filter Soot Accumulation P242F Diesel Particulate Filter Restriction Ash Accumulation e The vehicle operator may experience a MIL illumination due to one of the following DTC s P0101 Manifold Absolute Pressure Sensor Performance P0106 Boost Pressure Sensor Rationality P0191 Fuel Rail Pressure Sensor Circuit Performance Improved Water In Fue
191. rmance lack of power The bulletin discusses the troubleshooting procedures for a poor performance complaint After verification of engine system performance the bulletin outlines the criteria for a torque converter stall test for automatic equipped trucks and a 20 50 mph test for manual transmission trucks An adjustment procedure for the LDA a timing advance that is controlled by boost pressure is described The bulletin is known as the starwheel or balloon test by service technicians Erratic 3 4 or 4 3 shifts The bulletin discusses erratic shifting hunting between third and fourth gear The shift schedule is based on several inputs to the powertrain control module SEBC Diagnosis of the components is described If a throttle position sensor is required the replacement part number is 4746966 Vehicle surging when cruise control is engaged The condition may be caused by the calibration of the powertrain control module SEBC Replacement of the SEBC is covered in the repair procedure Lack of power poor acceleration in cold ambient temperatures Below 33 F some vehicles may be slow to accelerate or feel low on power The condition may be caused by ice forming at the fuel intake area of the fuel gauge sending unit module A revised module part number and repair procedure are outlined Erratic 3 4 or 4 3 shifter Note See TSB 18 06 93 A Poor performance lack of power Note See TSB 18 05 93 Engine rpm fluctuates when
192. rom buzzer module The condition is a buzzing noise in the rear radio speakers with the radio on ignition on and the door ajar If a buzzing noise is heard the repair involves replacing the buzzer module 1 CATEGORY 9 ENGINE TSB MODELS SUBJECT DESCRIPTION 09 07 96 94 95 BR Fuel injection pump oil supply bushing oil seepage 6 7 96 If oil seepage is diagnosed the bulletin describes the repair procedure using a special oil supply and removal tool CATEGORY 11 EXHAUST TSB MODELS SUBJECT DESCRIPTION 11 05 96 94 97 BR Diesel turbocharger diagnostic procedure 8 23 96 This information only bulletin guides the service technician thorough troubleshooting steps to properly diagnosis turbocharger situations Normal abnormal noises oil leakage acceleration and low boost are topics discussed in the bulletin CATEGORY 14 FUEL TSB MODELS SUBJECT DESCRIPTION 14 07 96 94 96 BR Low pressure fuel system diagnostic procedures 8 2 96 Too low a fuel supply to the Bosch P7100 fuel pump can affect performance Low rpm miss instability white smoke hard starting low power may be the result This bulletin gives the technician additional information to assist in diagnosis of the above problems CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS SUBJECT DESCRIPTION 18 11 96 96 BR Revised injection pump timing specifications 3 22 96 Arevision in the injection pump timing specification on Cummins engines
193. ror New mirror glass locking tab new removal procedure This bulletin applies to vehicles equipped with trailer tow mirrors sales codes GPD or GPG built after April 16 2007 and for any vehicle where service replacement of the mirror glass is required The trailer towing mirror assembly has a replaceable mirror glass As part of the replaceable mirror glass a locking tab has been added to the plastic backing on the mirror glass This change has been made to vehicles built after April 16 2007 This change is also being incorporated in service replacement of mirror glass This bulletin involves a discussion regarding new removal procedure when replacing the mirror glass on a trailer tow mirror 13 CATEGORY 23 BODY continued 23 028 07 Rev A 7 20 07 23 035 07 08 08 07 23 017 08 5 10 08 23 046 07 10 30 07 06 07 DR DH D1 1500 2500 3500 06 08 DC DM DR DH D1 08 DR DH D1 1500 2500 3500 06 08 DR D1 DC DH CATEGORY 24 Buzz like sound from front door speaker area when radio is on The sound in question will come from the interior door trim panel in the area where the radio speaker is mounted This condition may be misdiagnosed as a bad radio speaker The actual cause is typically the interface between the door trim panel sound insulation and the door water shield The repair procedure involves the addition of sound insulation to the door panel Exterior Lamp lens fogging Some custome
194. rs may report that vehicle exterior lamp assemblies are fogged with a light layer of condensation on the inside of the lenses This may be reported after the lamps have been turned on and brought up to operating temperature turned off and then rapidly cooled by cold water such as rain or the water from a car wash Lens fogging can also occur under certain atmospheric conditions after a vehicle has been parked outside overnight i e a warm humid day followed by clear cool night This will usually clear as atmospheric conditions change to allow the condensation to change back into a vapor Turning the lamps on will usually accelerate this process A lamp that has a large number of water droplets visible on most internal surfaces indicates a problem with the lamp sealing that has allowed water to enter the lamp In this instance the customer is likely to report that moisture in the lamp is always present and never disappears A lamp that exhibits internal moisture permanently should be replaced This bulletin supersedes technical service bulletin 23 041 06 dated September 27 2006 Tailgate retaining cables appear to be of unequal lengths This bulletin applies to vehicles built on or before May 7 2008 One of the two side tailgate check cables may not be properly tensioned This condition may cause the appearance that the tailgate cables are of unequal lengths The repair procedure involves setting the loose longer in appearance cable firmly i
195. rysler vehicles The Wireless Ignition Node WIN receiver on about 8 900 of the above vehicles may experience a condition where the Frequency Operated Button Integrated Key FOBIK may be removed prior to placing the automatic transmission gear shift lever in the PARK position This could result in unintended vehicle movement and cause a crash without warning To correct this condition the Wireless Ignition Node receiver must be inspected and replaced if necessary The new WIN must be programmed and all FOBIK transponders must be programmed so they are able to interface with the new WIN receiver CUSTOMER SATISFACTION NOTIFICATION K17 REPROGRAM HVAC CONTROL HEAD AND INSPECT REPLACE ACTUATORS Date September 29 2010 Models 10 DJ Ram Truck 2500 series 10 D2 Ram Truck 3500 series This recall applies only to the above vehicles built through May 22 2010 The HVAC mode door actuator gears on about 52 000 of the above vehicles may break and result in the inability to fully control the HVAC functions To correct this condition all involved vehicles must have updated HVAC control head software installed and the mode door actuators must be tested and replaced as required A Publication of the TURBO DIESEL REGISTER SAFETY RECALL K28 LEFT TIE ROD END Date February 2011 Models 08 10 DM Ram Truck 4500 5500 series cab chassis 11 DP Ram Truck 4500 5500 series cab chassis This recall applies only to the abo
196. s mini trip computer sales code CUS built after April 28 1999 Vehicles equipped with the compass mini trip computer are now having their compasses calibrated by the assembly plant making it no longer necessary to calibrate the compass during new vehicle preparation However in order to ensure proper operation of the compass it will still be necessary to set the variance of the compass prior to vehicle retail delivery Intermittent operation of oil pressure gauge This bulletin applies to vehicles equipped with the 5 9L Cummins 12 valve Turbo Diesel engine built before January 5 1998 The condition for correction is an oil pressure gauge that intermittently drops to zero pressure In addition the warning chime may sound when the oil pressure gauge drops to zero pressure and the check gauge lamp may come on Proper repair involves selectively erasing and reprogramming the Powertrain Control Module PCM with new software a calibration change Simplified compass mini trip computer calibration This bulletin applies to vehicles equipped with the compass mini trip computer sales code CUS The subject model vehicles are shipped from the assembly plants with the compass mini trip computer NOT calibrated This will be identified by CAL displayed on the compass mini trip computer To calibrate the compass mini trip computer drive the vehicle in a complete circle until CAL is no longer displayed on the compass mini trip computer Radi
197. s service bulletin 18 004 11 Rev A dated February 18 2011 This 12 21 11 bulletin applies to vehicles equipped with a 6 7 liter Cummins engine The software flash provides a number of software improvements enhancements These include P049D EGR control position exceeded learning limit P2002 Diesel particulate filter efficiency below threshold P2195 02 sensor 1 1 out of range high P2196 02 sensor 1 1 out of range low P2270 02 sensor out of range high P2271 02 sensor out of range low P241A 02 sensor 1 1 and 2 oxygen concentration mismatch P2609 Intake air heater system performance The previous TSB had software improvements for P046C EGR position sensor performance P051B Crankcase pressure sensor circuit range performance P0101 Mass air flow sensor A circuit performance P245B EGR cooler bypass status line intermittent P2262 Turbocharger boost pressure not detected mechanical The bulletin involves selectively erasing and reprogramming the engine control module ECM with new software A Publication of the TURBO DIESEL REGISTER 87 VEHICLE PEFORMANCE continued CATEGORY 18 TSB MODEL 18 045 11 All 6 7 liter diesel 10 19 11 equipped vehicles 18 005 12 11 DD DP 1 28 12 SUBJECT DESCRIPTION Cummins 6 7 liter Turbo Diesel common diagnostic process This bulletin supersedes service bulletins 09 002 09 dated June 13 2009 09 003 09 dated December 2 2009 and 11
198. same procedure The chime will sound four times as an audible indicator that the function is disengaged Note 07 09 truck engine ECMs were not equipped with the fan engagement software These engines would require the latest software update 18 020 10 in order to have the fan on capability 07 002 11 11 DJ D2 Transmission cooler hose weepage 8 13 11 This bulletin applies to vehicles equipped with the Cummins engine and an automatic transmission built between September 20 2010 and January 17 2011 Some of the listed vehicles have been built with a transmission cooler hose that may experience fluid weepage Inspect the upper transmission cooler hose Hot side line that runs near the battery for date code 2440 If the upper transmission cooler hose has date code 2440 on the hose verify whether or not the hose was built between 21 14 23 16 Time Stamp The date code may be on the lower side of the hose It may be necessary to use a mirror or rotate the hose This bulletin involves inspecting the upper transmission cooler hose for a specific date code and time stamp If found within the suspect range the transmission cooler hose must be replaced 08 014 10 10D1 DJ Radio locks up 6 29 10 This bulletin applies to vehicles equipped with a radio with sales code REN REZ The problem may be that the radio will not change stations or frequency intermittently The only function that will be available is volume control The repair in
199. se the dash silencer to locally overheat and cause an underhood fire without warning Repair All vehicles must have a dash silencer pad support bracket installed SAFETY RECALL H36 STEERING DRAG LINK INNER JOINT AND DAMPER BRACKET Date May 2009 Models 08 09 DH D1 2500 3500 series or 1500 Mega Cab 4x4 only 08 09 DC 3500 series Cab Chassis This recall applies only to the above vehicles built from February 19 2008 through October 30 2008 The steering drag link inner joint on about 32 700 of the above vehicles may fracture under certain driving conditions This could result in a loss of steering control and cause a crash without warning Also the steering damper bracket at the tie rod tube may loosen This could allow the bracket to slide on the tube and may cause increased vehicle turning radius Repair The drag link inner joint must be replaced and the steering damper bracket must be inspected and replaced if required SAFETY RECALL H46 MOPAR STEERING LINKAGE Date May 2009 Models 03 04 DR 2500 3500 series 4x4 05 DH 2500 3500 series 4x4 06 09 DH 2500 3500 series or 1500 Mega Cab 4x4 06 09 D1 3500 series 4x4 07 09 DC 3500 series Cab Chassis This recall only applies to vehicles that had certain Mopar service parts steering components installed During a prior service appointment a Mopar service parts steering linkage was installed on about 13 900 of the above
200. sealant PN 04883971 This bulletin provides specific routing of the sealant when replacing the engine oil pan gasket When replacing an oil pan gasket apply a 1 8 bead of RTV to the oil pan side of the gasket around the back of the engine extending up to the fourth bolt hole from the rear on each side as per the referenced diagram Crankcase Breather Overflow This bulletin applies to 98 02 BR Ram trucks equipped with the 24 valve Cummins diesel engine built after March 27 1998 ESN 56443872 Owners of 98 02 trucks equipped with the 24 valve Cummins diesel engine may experience engine oil overflow from the front crankcase breather when the vehicle is operated on an extreme downhill grade 36 5 or 22 slope grade Operation of this type for extended periods of time can cause enough engine oil depletion to damage the engine A kit containing all components necessary to eliminate the oil overflow has been made available The bulletin outlines the repair procedure that relocates the breather from the front of the engine to a new location on the driver s side tappet cover 45 CATEGORY 18 VEHICLE PERFORMANCE 98 5 02 BR BE TSB MODELS 18 019 01 9 3 01 18 014 01 98 02 BR BE 7 9 01 46 SUBJECT DESCRIPTION Cold idle engine warming This bulletin addresses selectively erasing and reprogramming the Engine Control Module with new software This bulletin applies to all Ram trucks built after De
201. sfactory compromise The vehicle should be evaluated under the loaded condition that produces the objectionable disturbance The repair procedure involves measurements at the transmission yoke front propeller shaft rear propeller shaft and rear axle The working angles should be adjusted to provide the lowest angle possible for the output shaft to front propeller shaft front propeller shaft to rear propeller shaft and rear propeller shaft to axle pinion The measurements will determine which direction to move the center bearing to optimize the angles Install the appropriate bracket to obtain the minimum working angle but still maintain at least 72 degree to ensure that there will be some movement in the U joint bearings 03 004 04 03 04 DR Axle whine 6 22 04 This bulletin applies to 4x2 2500 series 140 5 inch wheelbase vehicles equipped with diesel engine sales code ETC ETH and an automatic transmission sales code DG8 The problem is that some vehicles may exhibit rear axle whine at speeds between 35 and 70 mph The repair procedure involves identification of the pinion flange and propeller shaft that the vehicle is equipped with If a repair is necessary the propeller shaft is replaced using the chart listing the appropriate part numbers 03 003 06 03 07 DR Axle fluid level 10 20 06 This bulletin supersedes TSB 03 001 04 revision A dated 5 11 04 The axle fill holes on some 2004 Dodge Truck axles may be located consider
202. smission valve body or the entire automatic transmission was replaced with components manufactured after January 1 1998 This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module PCM with new software calibration changes 99Cal14 98Cal12 Improved speed control system sensitivity to set speed Some customers may complain that their vehicle speed control system may be too busy or drift more than 2 mph below or above the initial vehicle set speed Vehicle load and road terrain conditions may impact this issue The new PCM software improves the speed control system sensitivity so that the vehicle speed remains closer to its set speed with fewer engine rpm oscillations This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module PCM with new software calibration changes 98Cal12A 99Cal 17 There is no change to the Cummins CM551 Engine Control Module ECM software Common diagnostic trouble codes caused by an open fuse Analysis has revealed an issue with repeated repairs for the same Diagnostic Trouble Code DTC The DTC may be due to an overlooked open circuit used to power the component in question In most instances either the circuit fuse has been erroneously removed or the fuse itself is open blown The component in question and its circuit are often protected by two fuses It is usually the lower amperage fuse that is either missing or open The lower amperage
203. sound The customer may experience a creaking and or squeaking sound from the hood area when turning the vehicle and or going over rough terrain Inspect the hood and if a squeaking or creaking sound is observed when pressing the front of the hood perform the repair procedure which calls for the addition of anti squeak tape to the underside of the hood A Publication of the TURBO DIESEL REGISTER CATEGORY 25 EMISSIONS CONTROL TSB 25 001 09 10 20 09 25 001 10 7 9 10 MODEL SUBJECT DESCRIPTION 07 09 DH D1 MIL Illumination due to P2000 P2A00 and or P2A01 This bulletin supersedes service bulletin 18 035 08 dated September 13 2008 This bulletin applies to vehicles equipped with a 6 7 liter Cummins diesel engine The customer may experience MIL illumination Further investigation by the technician may find one or more of the following DTC s present e P2000 NOX Absorber Efficiency Below Threshold Bank 1 e P2A00 O2 Sensor 1 1 Circuit Performance e P2A01 O2 Sensor 1 2 Circuit Performance This bulletin involves verifying all TSB s related to high sooting issues have been properly addressed inspecting both Oxygen O2 sensors and either cleaning the sensors or replacing sensors and installing an O2 Sensor Blanket Shield on the exhaust pipe in the area of the front O2 sensor 11 DD Diesel exhaust fluid 11 DP This bulletin provides information regarding the diesel exhaust fluid DEF vehicle deliver
204. starting system Radio communication equipment installation recommendations This information only bulletin gives the dealership technician some guidelines for the installation of two way radio equipment Revised radio antenna mast installation procedure This information only bulletin advises the proper tightening torque 30 32 in lbs for the radio antenna mast for various Chrysler group products UConnect Hands Free module fails to respond due to module lock up This bulletin supersedes service bulletin 08 049 05 dated September 1 2005 and applies to vehicles equipped with UConnect Hands Free Communications sales code RSP that were built prior to October 2 2005 If the UConnect Hands Free Communications system does not respond when system activation is attempted by the customer the technical service bulletin gives the technician the proper repair technique to reset the hands free module Intermittent operation of electrical components due to ignition off draw IOD fuse not being fully seated This bulletin supersedes technical service bulletin 08 016 06 dated March 22 2006 The ignition off draw IOD fuse is used to prevent battery discharge during shipping and long term storage of vehicles If the fuse is not completely inserted partial contact of the fuse terminals could occur When the vehicle is prepped for customer delivery ensure that the fuse is fully engaged When the IOD fuse holder is depressed into the carrier an initial
205. supersedes technical service bulletin 23 39 97 dated June 27 1997 The problem covered is that the driver side power mirror vibrates or causes blurred images in driver side mirror while driving If removal of aftermarket bugscreen deflectors does not cure the problem a procedure for installing a mirror reinforcement bracket is described 08 11 98 98 BR Delayed operation of fog lamps 3 13 98 The fog lamps illuminate approximately two seconds after being turned ON with the headlamp LOW beams illuminated This condition may also occur when the headlamps are turned from HIGH beam to LOW beam with the fog lamps ON The repair involves checking the headlamp connector for proper wire location 08 13 98 98 BR Headlamp switch knob pulls out of headlamp switch 3 27 98 This bulletin applies to vehicles built before November 16 1997 Rotate the headlamp switch knob to the full dim position Then apply pressure to the side of the knob and pull the knob to turn the headlamps ON If the knob pulls out of the headlamp switch when the headlamps are turned ON replace the knob using the described repair procedure N 6 A Publication of the TURBO DIESEL REGISTER CATEGORY 8 ELECTRICAL continued 08 14 98 3 27 98 08 16 98 4 17 98 08 17 98 Rev C 12 30 98 08 21 98 5 22 98 08 35 98 6 24 98 08 36 98 6 24 98 08 51 98 11 27 98 08 54 98 12 30 98 A Publication of the TURBO DIESEL REGISTER 98 BR 89 93
206. t of lack of 3 4 up shift at 50 to 60 mph on the 92 MY trucks or complaint of deep throttle 2 4 up shift on late built 92 and 93 models could be related to the overdrive shift calibration Using the DRB scan tool verify the engine and transmission systems are functioning properly The powertrain control module SEBC may require replacement to updated part number 4746568 Four speed automatic transmission 4 3 downshift clunk The bulletin describes a clunk or harshness during 4 3 coast downshift at approximately 18 20 mph Verify all engine and transmission systems are functioning properly Repair as required Delayed up shifts and harsh engagement into drive or reverse The bulletin describes a repair involving adjustment of the throttle valve cable and replacement of the return spring 3 4 up shift noise with A 518 transmission A noise or rattle during 3 4 up shift or down shift may be the result of an overdrive clutch pack vibration Diagnose the vehicle to confirm condition and repair as necessary Replacement of transmission shift lever and stubshifter The shift lever and stub shifter are available as separate replacement parts If replacement is required use the component parts do not replace the transmission assembly Low reverse band wear Premature wear of the low reverse band may be the result of one of the overdrive transmission mounting bolts making light contact with the band strut resulting in incomplete release of the
207. te of manufacture of December 8 j 1999 Oil seepage may be noticed in the area of the oil fill cap This may be due to paint overspray around the oil fill opening of the cylinder head valve cover The paint overspray may cause an uneven sealing surface The corrective action involves using fine grit sandpaper to insure a smooth mating surface Another possible cause for the oil seepage may be a damaged oil fill cap o ring The o ring may be cut die to the presence of a sharp corner around the top edge of the cylinder head cover oil fill opening 37 CATEGORY 14 FUEL TSB MODELS SUBJECT DESCRIPTION 14 01 00 00 BR Thump bump sound heard 1 3 seconds after the vehicle comes to a stop 02 04 00 This bulletin applies to 2500 series Club Quad cab vehicles equipped with the 6 1 2 foot box built before December 1 1999 Customers may hear a thump bump sound that occurs 1 3 seconds after the vehicle comes to a complete stop In some cases the thump bump sound may be transmitted through the floor of the vehicle allowing the customer to feel the thump bump in the floor pan of the vehicle The sound will only occur when the fuel level of the vehicle is between and 7 8 tank of fuel Since the fuel level of the vehicle must be between 7 to 7 8 full the condition may be difficult to diagnose The repair involves replacing the fuel tank 14 02 00 00 01 BR Crack in diesel fuel filter housing cover caused by an improper servicing pro
208. teering to keep the vehicle from wandering is a condition the bulletin describes the diagnosis and repair procedure The repair involves adjustment of the over center and if necessary the worm thrust bearing preload adjustments on the steering gear Lower steering column noise and or minor lower steering column movement This bulletin applies to vehicles built before Dec 31 1996 and describes a lower steering column noise and or minor lower steering column movement If movement in the steering column is greater than the tolerance the repair involves adding a toe plate shim to the steering column TRANSMISSION TSB MODELS 21 12 97 96 97 BR 8 29 97 A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION Transfer case shifter buzz or rattle This bulletin supersedes TSB 21 13 96 dated 9 20 96 A buzz or clatter may be heard from the 4x4 transfer case shifter at an engine speed of approximately 2000 rpm The condition may worsen when the engine is under load On vehicles equipped with automatic transmission the diagnosis must be done with the transmission in overdrive and torque converter clutch engaged If necessary the correction involves bending the shift lever spring reaction tab outward to increase the spring tension on the shift lever 23 CATEGORY 22 WHEELS amp TIRES TSB MODELS 22 01 97 94 97 BR 6 13 97 CATEGORY 23 SUBJECT DESCRIPTION Tire and wheel runout Radial runo
209. teering column 19 008 05 02 06 DR Revised power steering system bleeding procedures Rev A This bulletin supersedes service bulletin 19 008 05 dated October 26 2005 The bulletin 11 2 05 discussed that Mopar Power Steering fluid 4 or ATF 4 MS 9602 is to be used in the power steering system of DR vehicles No other power steering or automatic transmission fluid is to be used in these systems Damage may result to the power steering pump and system if the incorrect fluid is used Do not overfill the power steering reservoir If the air is not purged from the power steering system correctly pump failure could result CATEGORY 21 TRANSMISSION TSB MODELS SUBJECT DESCRIPTION 21 023 05 06 Out of park sense alarm 11 11 05 This information only bulletin applies to vehicles equipped with a 5 9L Turbo Diesel engine sales code ETH This information only bulletin discusses an alarm for out of park transmission setting Vehicles with a diesel engine and an automatic transmission are equipped with an alarm that warns the customer upon exiting the vehicle that the transmission is not in the Park position This feauture will only be functional under the following conditions engine running foot off the brake pedal e driver s seat belt unbuckled e driver s door open When this feature is triggered the horn will sound and the high beams and turn signal lamps will flash This feature is standard equipment and cann
210. the accelerator pedal on diesel engine vehicles with the engine operating between 2000 and 2200 rpm The vibration may be more pronounced with the A C compressor on Operate the engine between 2000 and 2200 rpm If the vibration is present perform the repair procedure which involves installing a power steering hose containing a vibration damper 19 010 04 04 05 DR Power steering fluid contamination 11 29 04 This information only bulletin discusses the use of supplements to the power steering fluid Do not use fluids or supplements that contain Teflon as they will cause a restriction at the filter in the power steering system The power steering fluid used in Chrysler Group vehicles is an engineered product The addition of any unapproved fluids or supplements can interfere with the proper function of the fluid and cause damage to the steering system To ensure the performance and durability of Chrysler Group steering systems use only Mopar Power Steering Fluid 4 ATF 4 automatic transmission fluid or equivalent MS 9602 in the power steering system 19 003 05 03 05 DR In and out movement in steering column 5 3 05 This bulletin applies to vehicles built after December 1 2003 If there is a small amount of movement in the steering column when pulling the steering wheel toward you while seated in the driver s seat the TSB outlines the proper repair procedure which involves the installation of a steering retainer kit to the s
211. ticipated Compass mini trip computer indicates erroneous average miles per gallon distance to empty and or trip odometer This bulletin applies to vehicles equipped with the compass mini trip computer sales code CUS The display will show an erroneous number in the third digit from the right If repair is necessary the module is replaced Static inside speakers and or side speaker cuts out when power outside mirror operates This bulletin applies to vehicles equipped with the power audio amplifier sales code RDE and heated outside power mirrors sales code GTS built between September 7 1998 and November 3 1998 The problem discussed is that static can be heard in the side speakers and or the sound coming from the side speakers can cut out and or in extreme cases the radio can cut out with the radio in the FM mode when the power mirror is actuated to its end of travel The repair involves replacing the mirrors 21 CATEGORY 9 ENGINE TSB MODELS SUBJECT DESCRIPTION 09 06 98 98 BR Incorrect engine oil dipstick 10 30 98 This information applies to vehicles equipped with 24 valve Cummins diesel engines Some early 1998 24 valve diesel engines were built with an incorrect dipstick calibration This incorrect marking causes an overfilled condition of approximately 1 1 2 quarts when at the top end of the safe zone on the dipstick This overfill condition is not damaging to the engine The Cummins part number is stamped on the
212. tin cautions the dealer that damage to the door trim panel may occur if the door trim panel retainer clips are separated from the door without using a trim panel removing tool Cargo net eliminated from production This bulletin applies to standard cab vehicles and informs the dealer network that the cargo net is no longer a production item It can be purchased through the parts department using Mopar number 04761197 Wind noise whistle around grill area and or dimples on the grill painted surface opposite of the grill fasteners This bulletin applies to Ram trucks equipped with the sport package If there is a windnoise whistle occurring from the front of the vehicle at highway speeds between 45 65 mph or at slower speeds when driving into a headwind this bulletin describes the repair procedure CATEGORY 2 TSBs Issued During 1999 FRONT SUSPENSION TSB MODEL 02 06 99 94 00 BR Rev A 12 17 99 02 13 99 94 99 BR 09 10 99 CATEGORY 5 SUBJECT DESCRIPTION Front wheel bearing grease is evident on the bearing seal area This bulletin supersedes TSB 02 06 99 dated June 11 1999 The revisions include the addition of 4x2 models and additional model years This information only bulletin discusses the fact that front wheel bearings may be incorrectly diagnosed as faulty due to the evidence of wheel bearing grease on the bearing seal areas This grease purge is a normal design condition The factory fill of the beari
213. ts Wheel tire vibration may be caused by the wheels being off center on the wheel studs The repair involves a wheel centering procedure using two 90 cone nuts CATEGORY 23 TSB MODELS 23 04 95 94 95 BR 2 10 95 23 29 95 94 95 BR 6 9 95 23 43 95 94 95 BR 6 14 95 23 52 95 A 94 95 BR Standard cab only 23 74 95 95 96 BR 12 8 95 23 08 94 94 BR 1 28 94 23 32 94 94 BR 4 1194 12 BODY SUBJECT DESCRIPTION Rattle due to seat belt latch plate bumping trim The symptom is a noise due to the seat belt latch bumping against the trim when the belt is not in use The repair involves the addition of a sound deadener pad to the trim panel Cracked sunvisor support bracket retainer The bulletin involves the replacement of the visor bracket with a revised bracket Door operation not smooth or feels loose Visually inspect the door hinge area If the door hinge bushing has fallen out the bushing should be reinstalled and crimped to prevent reccurance Creaking noise or exterior noise from back of cab The condition is a sheet metal creaking or exterior noise from the back of the cab caused by verticle or horizontal cracks in cab back Using a hoist and a strong light look for cracks on lower portion of cab If cracks are noted four cab reinforcements and replacement cab isolators should be installed Interior film build up on windows Window film build up is caus
214. ucks rated at 8800 GVW The bulletin discusses rear leaf springs and shock absorber availability that will increase the height of the vehicle when the vehicle is at maximum GVW The bulletin gives specific part numbers for various applications CATEGORY 5 BRAKES TSB MODELS SUBJECT DESCRIPTION 05 03 97 94 97 BR Chassis dynamics diagnosis 3 17 97 The bulletin supersedes TSB 05 10 96 as revisions have been made to torque specifications and procedures The bulletin summarizes different conditions that can cause a vehicle to move to the right or left when not controlled by the driver A lengthy test procedure is outlined to isolate the cause of vehicle drift 05 04 97 94 97 BR Accelerated brake lining wear front versus rear 3 28 97 2500 3500 series This bulletin supersedes TSB 05 02 96A as the bulletin incorporates the use of revised brake linings for trucks with 80mm calipers typically found on 2500 4x2 trucks The bulletin discusses wear conditions repair procedures part numbers and rear brake adjustment procedures 05 07 97 98 BR Parking brake release handle does not fully return 9 22 97 The bulletin applies to trucks built prior to 8 15 97 If applicable the repair procedure involves replacing a park brake release lever with a revised part CATEGORY 7 COOLING TSB MODELS SUBJECT DESCRIPTION 07 03 97 All Engine coolant usage 5 9 97 This information only bulletin discusses the use of propylene
215. ule ECM with new software The new software will have improvements enhancements available for the following DTC s e P0101 Mass Air Flow Sensor A Circuit Performance e P2262 Turbocharger Boost Pressure Not Detected Mechanical P2457 Exhaust Gas Recirculation Cooling System Performance P245B EGR Cooler Bypass Status Line Intermittent e P049D EGR Control Position Exceeded Learning Limit e P2195 02 Sensor 1 1 Out of Range High e P2196 02 Sensor 1 1 Out of Range Low e P2002 Diesel Particulate Filter Efficiency Below Threshold for high altitude failures e P2270 02 Sensor 1 2 Out of Range High e P2271 02 Sensor 1 2 Out of Range Low e P241A 02 Sensor 1 1 and 1 2 Oxygen Concentration Mismatch e P2609 Intake Air Heater System Performance Vehicles flashed to address the above codes should be driven and repair validated If code s return follow diagnostic procedures available in DealerCONNECT TechCONNECT The software also updates the ECU with other improvements e WiTech turbo test revision ScanTool may report a code as stored even though the fault has been cleared by completing a significant number of drive cycles without a repeat occurrence e Active codes not always displayed correctly e Engine derate with IOD removed This will help prevent turbo damage due to oil thickening in cold climate start up on new vehicles in transit e Enhancement to reduce shift clunk at stop
216. ure controls during deSoot DPF Super deSoot feature to enhance the deSoot process e Improved air filter minder detection e Added turbo cleaning scan tool service procedure available through a diagnostic scan tool This procedure is available with version 10 02 due out in December e Many other enhancements CCN update required with J35 recall This bulletin applies to 07 and 08 vehicles equipped with a Cummins 6 7 liter engine This bulletin supersedes service bulletin 18 013 08 Rev A dated December 4 2008 Many improvements have been addressed with the latest engine control module ECM software addressed in Recall J35 The cab compartment node CCN may require updating in conjunction with the Recall This service bulletin discusses the procedure used to update the CCN The problem addressed with this bulletin is that the truck will not pass a Smog Check On Board Diagnostic OBD Test or Inspection and Maintenance check up This bulletin applies to 2006 and 2007 vehicles equipped with a 5 9 liter Cummins engine sales code ETC or ETH with Federal emissions sales code NAA built after January 1 2006 or Cab Chassis equipped with a 6 7 liter Cummins engine sales code ETJ built prior to January 11 2007 This bulletin supersedes service bulletin 18 038 09 dated December 19 2009 This revised bulletin will cover federal emissions EPA certified vehicles only Vehicles equipped with CARB California emissions have been re
217. ure to ensure parallel alignment of the right and left 8 9 11 10 11 DJ D2 DD steering tie rod ball stud housings The bulletin applies to 4x4 models of the 2500 3500 pickup 06 09 DH D1 truck and to all 3500 4500 5500 Cab Chassis trucks which have a solid front axle The overview 07 09 DC of this repair procedure The right to left tie rod ball stud housings must be aligned parallel to 05 DH one another and not exceed 3 degrees of combined parallelism This procedure is required 03 04 DR any time service is performed to either the tie rod or when performing a front end alignment or toe set procedure Failure to properly perform the parallel alignment procedure may lead to tie rod damage 19 003 11 10 11 DJ D2 Steering honk and or groan sound during low speed parking lot maneuvers 2 2 11 141 DD This bulletin applies to vehicles equipped with 6 7 liter Cummins engine built prior to November 23 2010 The customer may experience a honk and or groan sound coming from the steering system during low speed parking lot maneuvers This bulletin involves inspecting and if necessary replacing the power steering gear This bulletin applies to 4x4 models of the 2500 3500 pickup truck A Publication of the TURBO DIESEL REGISTER 83 CATEGORY 20 BODY TSB MODEL 23 024 11 11 DD DP 7 12 11 10 11 DJ D2 09 10 DM DC 09 DH D1 CATEGORY 25 SUBJECT DESCRIPTION Whistle and or high pitch windnoise at door near windshield A pillar This bulletin applies to
218. use two or more On Board Diagnostic OBD monitors report that they are not ready for testing This condition may cause the customer vehicle to not pass an Emissions M test The following is a list of OBD Monitors that may report as not ready for testing Non Methane Hydrocarbon NMHC Catalyst Monitor Nitrogen Oxide NOx Absorber Monitor Exhaust Gas Temperature Sensor Monitor Electrical Charging System Monitor EGR System Monitor Oxygen Sensor Monitor e Malfunction Indicator Lamp MIL due to one or more of the following Diagnostic Trouble Codes DTC s a P0101 Mass Air Flow MAF Sensor Rationality b P0128 Thermostat Rationality c U1421 Implausible Ignition Key Off Time Received gt p9Q29To The latest ECM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time CATEGORY 18 VEHICLE PERFORMANCE continued 18 035 08 9 13 08 18 001 09 1 21 09 07 08 DH D1 07 09 DC DM 3500 4500 5500 Cab Chassis A number of improvements have been made to the engine diagnostics Performing this Service Bulletin completely will enable these diagnostic improvements To determine if the vehicle has the latest software compare the software level to the following notes e If the vehicle in question is a 2
219. ut is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire Runout of more than the preferred specification may cause the vehicle to shake This information only bulletin provides the proper specification for runout BODY TSB MODELS 23 03 97 89 93 AD 2 14 97 94 97 BR 23 22 97 94 97 BR 414197 23 25 97 96 97 BR 5 2 97 23 27 97 94 97 BR 5 9 97 23 39 97 94 97 BR 6 27 97 23 61 97 94 98 BR 11 28 97 23 67 97 98 BR 12 6 97 23 68 97 98 BR 12 19 97 SUBJECT DESCRIPTION Difficult to clean light colored chalky residue from black plastic body components The discussion covers difficult to clean light colored chalky residue from exterior plastic body components that are molded in black especially those that are textured such as door handles mirrors roof rack attachments etc Frequently this chalky residue is actually an accumulation of car wax road grime etc trapped in the plastic grain The correction is to clean the component with a soft bristle brush and mild detergent liquid dish soap until the residue is gone Driver s side wiper blade contacts A Pillar This bulletin applies to vehicles built before Oct 15 1996 If the driver s side wiper blade contacts A Pillar or a popping s
220. utch pedal released The bulletin involves replacing the clutch disc with a revised part 06 001 07 07 Clutch system may over adjust causing difficulty engaging transmission gear 2 03 07 This bulletin involves replacement of the clutch system flywheel pressure plate and disc This bulletin applies to vehicles equipped with a 5 9 liter or 6 7 liter Cummins Turbo Diesel engine and the G56 manual transmission sales code ETH ETJ and DEG respectively and built on or before November 09 2006 A Publication of the TURBO DIESEL REGISTER 51 CATEGORY 6 CLUTCH continued The customer may experience difficulty attempting to engage a manual transmission gear This may be due to the self adjusting mechanism in the clutch system The self adjusting clutch mechanism may over adjust forward adjust This condition most often will occur within the first 1 000 miles of vehicle operation The bulletin describes the proper repair technique to replace the flywheel clutch plate and clutch disc CATEGORY 8 TSB 08 016 02 9 2 02 08 004 03 3 14 03 08 007 03 4 4 03 08 019 03 6 20 03 08 031 03 10 31 03 08 011 04 3 16 04 MODELS 02 03 DR 02 03 DR 03 DR 03 DR 03 DR 04 DR ELECTRICAL SUBJECT DESCRIPTION Horn chirp and erroneous alarm This bulletin involves reprogramming the forward control module FCM should there be an er roneous horn chirp when a door is open
221. utomatic trucks between 2 1 94 and 10 1 94 The condition is exhaust soot on the side of the truck A tail pipe extension is the part needed to remedy the situation Rear tailpipe support bracket cracking The condition is a rattle noise caused by a crack or break in the rear tailpipe support bracket area A revised tailpipe support bracket 5 2018458 is the part used for repair FUEL TSB MODELS 14 05 94 94 BR 4 8 94 89 93 AD 14 15 93 89 93 AD 14 02 90 89 90 AD 12 3 90 14 01 89 89 AD 10 2 89 CATEGORY 16 SUBJECT DESCRIPTION Use of low sulfur fuel The bulletin discusses the new for 1994 low sulfur fuel Fuel lubricity concerns are addressed as the use of diesel fuel additives to increase the lubricity of low sulfur fuel are not required Fuel leakage from the roll over valve vent The bulletin warns that repeated attempts to force fuel into the tank after the automatic shut off has engaged may lead to a condition where the fuel level in the tank is above the designed operating level Fuel may leak out of the roll over valve in this situation The repair involves raising the roll over vent location by installing fuel hose to the vent nipple and routing to a high location along the filler tube Accelerator pedal effort too high The bulletin describes the installation of revised parts to lessen the pedal effort If the truck has a Mopar aftermarket speed control kit the kit al
222. ve vehicles built through September 02 2010 The left outer tie rod end on about 15 500 of the above vehicles may fracture due to a misalignment condition Under certain driving conditions this may lead to a weakening and eventual fracture of the left outer tie rod ball stud A fractured tie rod end could cause a loss of directional stability and a crash without warning The left outer tie rod end must be replaced toe in must be set and the tie rod ends must be aligned CUSTOMER SATISFACTION NOTIFICATION L14 REPROGRAM HVAC CONTROL HEAD Date April 12 2011 Models 10 D2 Ram Truck 2500 series 10 DJ Ram Truck 3500 series This notification applies only to the above vehicles built with Manual Temperature Control MTC from March 18 2010 through June 24 2010 The Heating Ventilation and Air Conditioning HVAC control head software on about 10 330 of the above vehicles may cause the mode door actuator gears to make noise and or break This could cause the inability to fully control the HVAC functions To correct this condition the HVAC control head must be reprogrammed with new software SAFETY RECALL K33 POWER STEERING RESERVOIR CAP Date February 1 2011 Models 10 11 DC DM DJ D2 DD DP Ram Truck This recall applies only to the above vehicles equipped with a Cummins engine built at the Saltillo Assembly Plant G in the 11th VIN Position through October 05 2010 The power steering reservoir cap on ab
223. volves upgrading the software of the REN REZ radio 08 026 10 11 DD DJ DP D2 Park assist system for message clarity and false messages on 4x4 models Rev A This bulletin applies to vehicles built with the Parksense Rear Park Assist sales code XAA 12 18 10 Customers may not understand the EVIC message display Blinded This indicates that the Parksense Rear Park Assist sensors require cleaning The EVIC flash will change the display to indicate Clean Sensors The EVIC may display the message Press 4 Low when a shift into 4x4 is not allowed This message has no meaning on these vehicles The EVIC flash will prevent this message from being displayed This bulletin involves reprogramming the EVIC with new software 80 A Publication of the TURBO DIESEL REGISTER CATEGORY 8 ELECTRICAL TSB 08 028 10 Rev A 11 2 10 08 001 11 Rev A 3 5 11 08 003 11 Rev B 3 17 11 08 018 11 Rev A 7 1 11 08 024 11 Rev A 7 1 11 08 015 11 4 6 11 08 033 11 6 22 11 08 049 11 8 12 11 A Publication of the TURBO DIESEL REGISTER MODEL 10 DJ DX D2 10 11 DJ D2 10 11 DD DJ DX D2 11 D2 10 11 DJ D2 11 DD DJ DP 11 DJ D2 DD DP 11 DJ D2 DD DP 11 DJ D2 DD DP DX SUBJECT DESCRIPTION RBZ radio software enhancements This bulletin applies to vehicles built with a radio that has a sales code RBZ The customer may experience one or more of the following problems The display may appear to be di
224. w P061A ETC Level 2 Torque performance P0607 ECU Internal Performance The latest PCM software will include the following operational and diagnostic improvements Improve engine cooling capability and prevention of over temp condition P0217 Coolant Temperature Too High when operating with snow plow New feature that allows for customer A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE continued 18 024 09 07 09 D1 DH 8 6 09 selectable remote PTO speed if equipped The latest ECM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time To determine if the vehicle has the latest software compare the following notes e If the vehicle in question is a 2007 model year vehicle then compare the current PCM software level part number to one of the following part numbers or with a higher suffix 52300430AX or higher DC 3500 6 7L Manual Transmission 50 State 55300434AX or higher DC 3500 6 7L Automatic Transmission 50 State e If the vehicle in question is a 2008 model year vehicle then compare the current PCM software level part number to one of the following part numbers or with a higher suffix 61300430AK or higher DC 3500 6 7L Manual Transmission 50 State 61300434AK or higher DC 35
225. ws from contact with the door inner belt weather strip Some vehicles may have been built with the weather strip not having a coating of soft protective flocking on the surface that contacts the window The repair involves installing a revised door inner belt weather strip Bug deflector wind whistle Some vehicles equipped with a factory installed hood mounted bug deflector may exhibit a whistling sound coming from the front of the vehicle The repair procedure involves installing foam tape to the bug deflector n CATEGORY 23 BODY continued 23 003 04 1 27 04 23 004 04 23 011 04 23 029 04 8 2 04 23 005 05 1 31 05 23 022 05 4 2 05 23 049 05 10 12 05 23 009 06 2 14 06 23 014 06 3 8 06 12 02 04 DR 04 DR 03 04 DR 04 DR 03 04 DR 05 06 DR 04 05 DR 04 05 All Chrysler Group Vehicles Water leak at grab handle Water may enter the vehicle through the secondary door seal retainer or the roof seam onto the headliner and run down the A pillar coming out at the grab handle The repair involves sealing holes in the roof panel Cup holder binds or sticks If the cup holder binds will not open or only opens partially the instrument panel trim should be adjusted to provide clearance for the cup holder Bug deflector loose rattling This bulletin applies to vehicles equipped with a factory installed bug deflector sales code MXB Th
226. x door is closed The proper diagnosis involves performing an ignition off draw IOD test as described in the 98 Service Manual If necessary the bulletin outlines the installation of two spacers between the glove box lamp switch bracket and the instrument panel glove box opening upper reinforcement Remote keyless entry transmitter batteries discharge prematurely This bulletin applies to vehicles built prior to August 15 97 and describes a condition where the Remote Keyless Entry transmitter batteries discharge in approximately 6 weeks The repair calls for replacement and reprogramming of the transmitter EXHAUST TSB 11 01 97 5 16 97 CATEGORY 14 MODELS 94 97 BR SUBJECT DESCRIPTION Whine or howl while driving at highway speeds This bulletin applies to vehicles equipped with the diesel engine option Some vehicles may experience a whine or howl noise while driving at highway speeds This noise may be miss interpreted as turbo whine After proper diagnosis of the condition the bulletin s repair procedure involves replacement of the muffler FUEL TSB 14 07 97 7 18 97 MODELS 94 97 BR SUBJECT DESCRIPTION Diesel fuel injection pump tampering This information only bulletin applies to inline fuel injection pumps as found on 94 thru early 98 model trucks The bulletin stipulates that there are only a few items on the pump that are serviceable low idle adjustment timing adjustment thrott
227. xle lubricant This bulletin applies to 2002 2003 DR Ram trucks equipped with the 9 rear axle and trailer tow package It is critical to optimum performance in trailer towing conditions that when service is being performed on the 9 1 2 rear axle on 2002 2003 DR Ram trucks the axle must be refilled with Mopar 75W 140 synthetic gear and axle lubricant PN 04874469 Five ounces 148ml of Mopar friction modifier PN 04318060AB must also be added to vehicles equipped with the trac lok style rear axle Launch shudder This bulletin involves adjusting the propeller shaft working angles and applies to vehicles equipped with a two piece rear driveshaft The problem is described as a drive line shudder or vibration while accelerating from a stop The condition is most noticeable under heavy throttle acceleration and is usually present only at low speeds below 25 mph Vehicles equipped with a two piece driveshaft are designed to minimize reaction forces that result from the universal joint transmitting torque at an angle These forces cannot be eliminated entirely because of the necessity to compromise joint angle selection between curb and design loading conditions U joint angles change depending upon the amount of weight applied to the vehicle bed A Publication of the TURBO DIESEL REGISTER CATEGORY 3 AXLE DRIVELINE continued Therefore U joint angle readings may need to be taken with different vehicle loads in order to obtain a sati
228. y Plant on or before August 31 2000 Ram trucks built at the Lago Alberto Truck Assembly Plant on or before September 6 2000 The repair involves replacing the Central Timer Module CTM with a revised part ENGINE CATEGORY 9 TSB MODELS 09 02 00 99 00 BR 02 18 00 09 03 00 00 BR 02 18 00 A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION A heavy oil or fuel like odor coming from the diesel engine compartment This bulletin applies to vehicles equipped with a 5 9L diesel engine The problem is a heavy oil or fuel like odor coming from the engine compartment This condition may occur after the engine oil has been changed The odor appears to reduce in intensity as the engine oil ages This aging usually occurs between the first 300 to 500 miles following the oil change The odor condition is the result of certain diesel engine oil additives These oil additives are blended with the base oil during the manufacture of the engine oil Some diesel engine oils with the American Petroleum Institute quality rating of CH 4 or CH 4 may be more prone ot exhibiting the odor condition The DaimlerChrysler recommended diesel engine oil p n 04798231 or p n 0479832 is formulated to minimize the heavy oil odor condition Engine oil seepage past the oil fill cap on 5 9L 24V diesel engine This bulletin applies to vehicles equipped with a 5 9L 24V diesel engine built before engine serial number 56664950 with a da
229. y fill guidelines The vehicle is equipped with a Low DEF warning system that notifies the driver when the level of DEF drops below approximately 2 5 gallons The warning system includes warning messages displayed by the EVIC and audible chimes The first level warning displays the message Refill DEF Engine Will Not Restart In XXX Miles If the vehicle is driven too long with low DEF the message Refill DEF Engine Will Not Start will be displayed At that point the engine will no longer restart if it is shut off A minimum of 2 5 gallons of DEF will need to be added in order to be able to restart the engine The following diagnostic trouble code may be displayed on a Diagnostic Scan Tool if the level of DEF was low e P203F Diesel Exhaust Fluid Reductant Level Too Low When this code is set the Powertrain Control Module PCM initiates a countdown that will inhibit an engine restart if the DEF system is not serviced within 500 miles e P1C70 SCR Error Detected Engine Disabled When this code is set the PCM commands the EVIC to display the Refill DEF Engine Will Not Start message The message will continuously display when the counter reaches zero and will be accompanied by a periodic chime The engine will not start after it has been turned off unless up to 2 5 gallons of DEF is added to the tank DEF has a temperature dependent shelf life that shortens when exposed to elevated temperatures As temperatures

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