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CATEGORY 8 ELECTRICAL...Continued

1. 62 NEW OWNERS CORNER Lube and service basics for your new truck Always follow the recommendations in your Owner s Manual Below are excerpts from the manual and further TDR commentary Breaking in your new truck Drive moderately for the first 1 000 miles to assist in breaking in the powertrain brakes bearings etc Do not use full throttle for extended periods and vary speeds frequently After the first 1 000 miles use the truck normally Particularly during the breaking in pe riod avoid extended idling Your Cummins engine will break in faster if you haul or tow with the truck The engine will not be fully broken in and will not reach its full power and fuel mileage potential until it has operated for approximately 10 000 miles Fuel Use only 2 diesel fuel As an option in winter you may use 2 diesel fuel blended with 1 diesel or kerosene or 2 diesel otherwise treated to lower the pour point of the fuel Use 1 diesel fuel for extreme cold weather operation only Always fill at popular locations that sell a lot of fuel Diesel that has not been subject to long storage should contain less moisture and sediment Engine Oil Use any high quality lube oil diesel rated 15W 40 with the API donut symbol CH 4 SH or better such as Cummins Premium Blue Shell Rotella T Chevron Delo 400 For very cold weather operation you may use a diesel rated 10W 30 meeting the same API spec as above Do not use synthetic oil if
2. 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 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 Th
3. AWORD ABOUT THETURBO DIESELREGISTER How did the Turbo Diesel Register get its start First off I m an automotive enthusiast An automotive enthusiast that was in search of a tow vehicle for my admittedly small collection of automobiles As you can imagine the search for the right tow vehicle took me in the direction of the Dodge Cummins Turbo Diesel My search was aided by the fact that my previous job was in the diesel engine profession as a Cummins distributor product support representative Do have a good knowledge of the Turbo Diesel engine Well maybe lIl let you be the judge Back to the story As an automotive enthusiast am a member of a handful of car club register type publications In addition subscribe to just about every car and truck monthly publication in hopes that can learn something more about my vehicles The only vehicle owned that didn t have its own club was the Turbo Diesel The light goes on Why not start a Turbo Diesel club The light flickers know the immediate answer not enough time no money and who would write the articles Needless to say the idea got put on the back burner Another great idea but Pre 4 Juyers gt mm ce 4 Juide Table of Contents Looking at the Changes 3 Buying a Used Truck 55 8 Dodge Technical Service Bulletins 10 Years 95 and Prior cccccssscscseeeeees 11 Lo
4. Six speed manual NV5600 6th overdrive late availability and soon withdrawn from sale Maximum Tow Ratings All configurations and axle ratios of manual transmission trucks 20 000 GCWR All configurations of automatic transmission trucks 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR Note Maximum permissible trailer weight will vary by model and options For example 4x4 models are rated for lower maximum trailer weights than 4x2 models and extended quad cab models are rated for lower maximum trailer weights than standard cab models Highest trailer weight rating is for a 2500 regular cab 4x2 manual transmission long bed 14 150 pounds trailer Lowest trailer weight rating is for a 3500 quad cab 4x4 automatic transmission 3 54 axle 9 050 pounds trailer Cab Chassis Models Available in regular cab only 2500 is 8 800 GVWR 56 C A dimension 3500 is 11 000 GVWR and available in 60 and 84 C A dimensions Tow ratings are same as above Comments Six speed transmission removed from sale due to quality control issues Users find the 4 10 axle ratio is best for towing with the 24 valve engine 2000 Turbo Diesel What is New Optional fold away towing mirrors Optional automatic dimming rear view mirror Revised front disc brakes with two piston calipers 4 wheel anti lock brakes standard on 3500 series trucks Added radio with CD changer controls Changer is a dealer installed Mopar accessory Deleted body side
5. 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 18 11 99 98 99 BR Slow acceleration or lack of power while towing or hauling a heavy load 05 28 99 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 333035303U 333036303 333037303 If the calibration level is 98T17 then this TSB does not apply 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 18 21 99 98 99 BR 5 9L 24V Cummins diesel low power or poor performance diagnostic The vehicle oper
6. 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 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 t
7. 6 29 92 18 10 92 A 9 8 92 18 11 92 7 13 92 18 17 92 9 8 92 18 18 92 10 19 92 18 15 92 MODELS 94 95 BR with automatic transmission 94 BR with automatic transmission 94 BR 91 93 AD 91 93 AD with automatic transmission 92 AD 91 92 AD 91 92 AD with automatic transmission 91 92 AD 91 AD 91 92 AD 91 AD 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
8. 7 You ve ever hit a deer with your truck deliberately 8 There are more than four hats in the rear window of your truck 9 Directions to your house include turn off the paved road 10 Your hood ornament used to be a bowling trophy From You Might Be A Redneck If by Jeff Foxworthy Foxworthy s Southern humor can be found at bookstores everywhere Buy his books for some serious fun 28 TSB s Issued During 97 CATEGORY 2 FRONT SUSPENSION 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 trucks 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
9. Cold Starting Turn on key and when wait to start light goes out start the engine You may need to apply light throttle up to 1 000 RPM to keep the engine running if it is very cold Allow two or three minutes of idling time for oil to circulate in the engine before driving away Use light throttle until engine has fully warmed up Washing and waxing New paint is soft for the first 30 to 60 days after spraying and should cure up to three months before gaining full strength Wash your new truck with clean water on a cool paint surface for the first 30 days Use a soft cloth with a nap surface If the truck is very dirty use a mild car wash soap diluted in water and applied with a soft cloth Do not wax your truck for 30 days then use a cleaner wax which is suitable for clear coated finishes In this case logic prevails if 3 is good then 4 is better Mopar Cummins Fleetguard Part Number Reference Notes This table Includes part number supercessions as of 8 30 01 Part numbers at the top are Mopar middle are Cummins bottom are Fleetguard For lube filters the numbers on the left are paper cellulose media design The numbers to the right are Microglass or StrataPore design Belt part numbers are Dayco Hose part numbers are Dayco and Mopar FUEL FILTER LUBE FILTER AIR FILTER BELT MODEL YR PART PART PART Assumes A C HOSES THERMOSTAT 05015581AA 05016547AB 4728
10. Continued 08 14 98 98 BR Clicking rattling or ratcheting noise coming from the seat belt retractor 3 27 98 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 08 16 98 89 93 AD Installation of radio transmitting equipment 4 17 98 94 99 BR 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 08 17 98 94 99 BR Airbag on off switches Rev C This bulletin supersedes technical service bulletin 08 17 98 Rev B dated September 18 1998 12 30 98 This information only bulletin is provided to identify the parts and procedures necessary to deactivate airbags authorized by
11. and special tools needed Trucks equipped with the five speed manual transmission are prone to excessive gear lash in the driveline This can cause hard jerking when the throttle is suddenly lifted particularly when hauling or towing heavy loads This condition is normal In addition to gear lash the rubber bushed drivetrain windup is partially responsible Draining and refilling the automatic transmission oil pan is not fun for the backyard mechanic because the pan cannot be drained before removal B amp M offers a drain plug that can be inexpensively installed in the pan to make fluid and filter changes easier and cleaner The plug is available from Geno s Garage In vintage 94 to 98 trucks with automatic transmissions cooling lines have plastic quick disconnect couplers that can fail under high heat conditions causing a loss of transmission fluid A revised coupler is available from Dodge parts Or you can make your own using weatherhead brass fittings of the appropriate size available at most auto parts stores The fittings are listed under the trade name Dana Weatherhead 68x8x4 Caution we have seen reports that the hard fittings can cause stress cracks in the transmission line due to vibration When draining the lube from five speed manual transmissions remove the PTO cover from the side of the transmission Start with the bottom bolt as it acts as a drain plug Refill with synthetic gear oil in 75W 90 or
12. nozzle on it The solid stream results in fewer water beads on the waxed surface Clean window glass with a mixture of ammonia and warm water applied with a cloth or sponge Dry the glass with old newspaper pages Cheap and effective To clean your engine use a solution of Simple Green in water Spray it on a cold engine let it sit briefly hose it off Contributed by Don Mallinson and Robert Patton Installing a pyrometer gauge in the exhaust provides the greatest accuracy in assessing exhaust temperature Pyrometer temperature should read less than 300 degrees before shutting down when measured in the elbow after the turbocharger Gauges are available from Geno s Garage Call 1 800 755 1715 Extended idling over 10 minutes is not recommended by Cummins PREVENTIVE MAINTENANCE AREAS FOR DODGE TRUCKS All vehicles develop maintenance problems that require special attention to prevent breakdowns or part failures The following is a list of special areas on Turbo Diesel trucks that warrant attention These items have been discovered through miles and miles of driving by the TDR membership This list is categorized in the same classification as Dodge s Technical Service Bulletins The list was compiled by TDR correspondent Jim Anderson This is an excellent complement to Jim s research in last issue s Turbo Tips where he gave us a Collection of low cost solutions to common problems we encounter 7 COOLING Installing a piece of metal
13. seal the edge from unraveling This tip will not work on carpet with all natural fibers Practice on a scrap piece first Wrap a fingertip with duct tape glue side out TAKE IT OFF When you disassemble any piece of mechanical equipment you will end up with a bunch of random fasteners and pieces and can easily forget your re assembly order or you can lose one or more fasteners Use several small plastic tubs to hold stuff and or a large plastic tray where parts and fasteners can be laid out in the order they were removed Just turn the tray around for re assembly in order If you leave your worksite cover the tray or tubs with plastic food wrap to keep things from being disturbed For long term disassembly a freezer bag marked with the content description is a good alternative STUBBORN FASTENERS If your screwdriver slips off a Phillips or slot head screw when you try to loosen it put a bit of grinding compound in the slots to increase the screwdriver s grip on the fastener Another method is to strike the end of the screwdriver with a hammer while twisting it to break the fastener loose This works particularly well on aluminum fasteners or with steel fasteners in aluminum Better yet purchase an impact screwdriver to properly loosen those stubborn fasteners If you are trying to install a screw in an inaccessible place tape the screw to the screwdriver point insert the screw in its hole and turn it in The tape will
14. 80W 90 weights with a GL 4 rating Often members will ask about the GL 4 rated Castrol Synthetic gear lubricant 75W 90 specified for the five speed NV4500 manual transmission If the GL 4 classification is good shouldn t a GL 5 rated lubricant be better It may seem reasonable but in the case of the NV4500 gearbox not necessarily so The GL 5 oil contains twice the amount of sulfur phosphorous additive package as GL 4 At high temperatures the phosphorous plates out and reduces the coefficient of friction of the synchronizer rings New Venture Gear has seen this on shift stand tests Since there s twice as much of it there s more of a detrimental effect compared to GL 4 23 BODY Because a diesel engine vibrates more than its gasoline engine counterpart all fasteners should be checked periodically for tightness Also body fasteners and bracket fasteners which might vibrate in sympathy with engine vibration should be checked for tightness If the GL 4 classification is good shouldn t a GL 5 rated lubricant be better MECHANIC S TIPS Here s a collection of tips to help the mechanic handyman while working on his or her vehicle These tips have been collected by the editor over a period of years from many different magazines and other sources and have been organized into categories for easier reference WORK ENVIRONMENT First here are some tips from the pros about your work environment e Never wear rings
15. 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 08 26 00 00 01 BR Central timer module electrically locks up 09 29 00 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 Assembly 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 CATEGORY 9 ENGINE TSB MODELS SUBJECT DESCRIPTION 09 02 00 99 00 BR A heavy oil or fuel like odor coming from the diesel engine compartment 02 18 00 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 re
16. Bugscreen deflectors are designed to disrupt airflow which can lead to mirror antenna vibration 08 24 95 94 95 BR Accessory frame ground jumper wire 9 30 95 The bulletin discusses a frame ground jumper 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 bo 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 94 A 5 20 94 08 10 94 2 18 94 08 17 94 4 1 94 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 14 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 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 recom
17. Do the brakes pull to one side Does the truck steer correctly While driving note if there is excessive smoke from the exhaust Black smoke indicates overfueling or a clogged air filter White or gray smoke indicates excessive oil getting by the piston rings or an injection pump problem A puff of smoke of any color at startup is normal but should abate when the engine warms Walk around the truck immediately after the ride and note any smells of hot dragging brakes or leaking fuel A hot oil smell can indicate an oil leak onto the exhaust system Don t be embarrassed to ask to put the truck up on a lift for a more thorough inspection or to take the truck to a trusted mechanic for a professional inspection A professional independent inspection for a fee is cheap insurance that you are making a wise purchase decision After you are fully satisfied that the truck is what it is represented to be move on to the next step 10 Contact the Owner There are many possible reasons why this particular truck came to be for sale and it is up to you to determine the true reason Is the owner financially able to afford a new vehicle with more fancy gadgets or was the owner tired of fixing a problem or problems repeatedly Is the owner simply selling a vehicle that is no longer needed It is up to you to find out When you find a likely candidate and your search narrows to a specific vehicle you may want to buy consult your list again to m
18. 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 18 29 97A 96 98 BR Vehicle bucking on 96 thru 98 trucks with the Cummins engine and a manual transmission 12 5 97 with Cummins engine This bulletin supersedes TSB 18 29 97 dated 10 17 97 The condition to be corrected is one and five speed where the vehicle may exhibit a bucking or jerking condition while under light acceleration or transmission 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 SUBJECT DESCRIPTION 19 08 97 96 97 BR Clunk rattle felt in steering column wheel 5 30 97 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 a
19. NHTSA Airbag deactivation is a customer pay procedure 08 21 98 98 BR Radio Interference to from two way radio receivers 5 22 98 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 08 35 98 98 BR Instrument cluster bezel breaks when removed 6 24 98 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 08 36 98 89 93 AD Use of two digit calendar year codes in automotive computers 6 24 98 94 99 BR 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 aut
20. 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 08 37 99 94 00 BR Airbag On Off Switches 11 12 99 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 08 39 99 00 BR Communications may stop between the JTEC PCM and a generic scan tool 12 10 99 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 39 CATEGORY 8 ELECTRICAL Continued 08 42 99 98 99 BR The fuel gauge reads full for an excessive period of time 12 17 99 This bulletin applies 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
21. 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 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 MODELS 94 95 BR 94 95 BR 94 BR 94 BR 91 92 AD 89 AD with automatic transmission ENGINE SUBJECT DESCRIPTIO
22. a wealth of information How to join Please fill out and mail the order form below or register on line at Part Number Reference 63 www turbodieselregister com Robert Patton TDR Editor es es a a ee 4 Join Us Today Name An annual subscription to the Address Turbo Dlesel Register is 35 00 City State Zip Please complete this subscription form and enclose it in an envelope Phone Home along with your check or money order payable to Work TURBO DIESEL REGISTER 3651 Peachtree Parkway Truck Year Model Suite E 331 Suwanee Georgia 30024 c Payment Enclosed 770 844 1600 Ll Bill my Mastercard VISA INFORMATION SUBSCRIPTION LINE Exp Date LOOKING AT THE CHANGES A TURBO DIESEL BUYER S GUIDE by Jim Anderson Aside from the quarterly column and articles that write for the TDR also serve as the e mail and call back guy Yep that means get lots of correspondence from those interested in the TDR as well as those interested in the purchase of a truck With the ever changing ownership of vehicles the idea of a Turbo Diesel Buyer s Guide makes perfect sense To that end the editor asked me to do a study of changes by model year to Dodge Cummins trucks Since its1994 introduction the current body style Dodge Ram pickup has undergone many changes and modifications To properly compile such a list changes for each model year seem to build on each preceding model year a
23. available in 60 and 84 C A dimensions Tow ratings are same as above with maximum for 3500 six speed 4 10 axle of 21 500 GCWR Comments The six speed transmission remains on back order due to high demand New disc brake rear axle and standard 4 wheel ABS greatly enhances stopping ability on 01 5 trucks All truck functions are increasingly controlled by computer electronics Conclusion More Data As a note from the editor I d like to thank Jim for his efforts in compiling the data for the Buyer s Guide pages Researching through the details in the Dodge data books was a difficult task And the task is not yet complete It is our hope to use this data as the springboard to an ever changing document on the TDR s web site We will ask members to post their positive experiences with their year model trucks Factual input from members concerning the minutiae of changes for a given model year will be documented Look for this document as a start to a much larger discussion of used Dodge Turbo Diesels As the Buyer s Guide is incorporated into the web site it will serve as a much needed resource TDR members will be able to help prospective used truck buyers by sharing experiences Thanks members BUYING A USED TRUCK By Jim Anderson When you buy a new truck you are protected by a manufacturer s warranty and the integrity of the dealer from whom you purchase When buying a used vehicle you are much less protected
24. be set according to the engine data plate Poor performance 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
25. bulletin 08 06 99 dated March 5 1999 Customers 12 17 99 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 08 16 99 99 BR BE Inoperative or intermittent remote keyless entry RKE transmitter 6 11 99 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 08 17 99 99 BR Compass mini trip computers no longer need calibration during new vehicle preparation 05 28 99 This information only bulletin applies to vehicles equipped with the compass 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 wil
26. by the law and frequently will have no warranty from a manufacturer to fall back on in case of a problem Therefore you must be much more careful in inspecting your intended purchase The benefits to the used truck purchase the vehicle cost is less than new used trucks typically have had the new vehicle bugs fixed and they represent greater value for the dollar since the initial depreciation has already been taken by the first owner A whole market has sprung up in the last few years for used Dodge Cummins turbo diesel trucks fueled in part by the high cost of a new one and by the fact that even trucks with high mileage have lots of life left in them due to the legendary reliability and durability of the Cummins diesel This has had a side benefit in that used Dodge Cummins trucks have retained a greater percentage of their resale value than the average for all diesel trucks and they command high prices on used vehicle lots This means you may pay more for your truck but will get more for it when you eventually become a seller A well maintained truck with high mileage should not be disregarded as a good value since with good regular maintenance these trucks can reliably run half a million miles and more Vehicle purchasing can be divided into two parts One is buying the metal and the other is buying the money used for the purchase Your goal as a used truck purchaser is to get both parts right How do you select just the righ
27. eventually fall off A dab of grease or body putty may hold a light screw the same way Want to prevent a fastener from rusting after it has been installed Simply coat the head with clear nail polish Clear nail polish also works as a thread locker Coat the threads then quickly install the fastener For removing rusty nuts and bolts always use penetrating oil first and let it soak a bit before trying to break them loose If you re trying to fish a part or fastener out of an inaccessible place simply wrap some duct tape sticky side out around the end of a straightened coat hanger It may take a couple of tries but if the tape will stick to the part the part will come out with the coat hanger This works better than a magnet if you are working in an area full of metal Ever tried to hold a nut in a tight spot while threading a bolt into it Wrap a fingertip with duct tape glue side out or make a loop of the tape to stick it to your fingertip then place the nut on the tape The nut will stay put and not rock around while starting the bolt threads 59 60 ELECTRIC TIPS When taping a bundle of wires together coat the tape end with clear nail polish to keep it from coming loose If a vehicle battery is constantly boiling over check and clean the ground from the alternator and or voltage regulator to the vehicle frame A poor ground connection will cause the alternator to put out too much juice Measuring alternator outp
28. fitting on trucks built after 3 20 95 and superseded bulletin 21 02 95 3 31 95 CATEGORY 23 BODY TSB MODELS SUBJECT DESCRIPTION 23 01 96 94 96 BR Replacement cargo box information 1 5 96 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 23 02 96 94 96 BR Creak or tick noise from right side instrument panel 1 19 96 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 23 09 96 96 BR Seatbelt buckle difficult to engage with one hand 2 2 96 Clubcab with a J in The driver side power seat may have a seat belt buckle that may be difficult to latch The repair the VIN at position 11 involves replacement of the seatbelt buckle and built prior to 10 6 95 23 21 96 94 96 BR Tailgate difficult to close in cold weather 3 29 96 At less than 5 F the tailgate latch stop bumper may be too stiff to allow for easy closure Inspect and replace bumper stop 23 27 96 96 BR Windnoise whistle around grille area 4 19 96 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 hoo
29. free and application blanks are available at all Flying J locations 55 56 18 VEHICLE PERFORMANCE Interested in improving the highway fuel mileage of your Dodge Joe Kubina Aerodynamic Development Engineer at Chrysler Corp says removing or laying down the tailgate on your truck will not improve fuel mileage and in fact could worsen it It seems the Dodge body shape is designed to flow air properly across a closed tailgate to maximize highway fuel economy 21 TRANSMISSIONS Michigan TDR member Paul Refer wrote in to say his automatic transmission would not go into overdrive after a cold start in very cold weather The editor pointed to the Owner s Manual that says If the vehicle is started in ambient temperatures of 5 degrees F or below the overdrive will not turn on This protects the transmission from damage if the cooling system freezes Overdrive operation will resume when the ambient temperature has risen to approximately 2 degrees F If you tow or haul heavy loads with an automatic transmission a transmission temperature gauge is a must Reluctant to cut a hole in the oil pan to install the sensor Member John Holmes tested a gauge sender unit in which the sender is installed on the transmission oil dipstick Slick and it works Available as a kit from Geno s Garage Call 1 800 755 1715 When installing a new automatic transmission pan gasket or almost any other gasket that doesn t want to stay in
30. greater than 0 Vehicle speed greater than 0 mph Coolant temperature is greater than 79 C 175 F CATEGORY 21 TRANSMISSION TSB MODELS SUBJECT DESCRIPTION 21 004 01 01 BR Overdrive disabled to improve transmission reliability during cold temperature operation 02 16 01 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 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
31. his service efforts A TSB is not an implied warranty TSB 02 05 95 5 15 95 02 02 94 2 11 94 02 07 94 6 15 94 02 08 94 7 22 94 02 20 94 12 2 94 02 02 91 1 28 91 02 06 90A 12 17 90 02 09 90 11 19 90 TSB s Issued During 95 and Prior MODELS 94 95 BR 4x4 4x2 Cab Chassis 94 BR 94 BR 94 2500 BR Cab Chassis with sales code XBC 94 BR 92 AD 2wd vehicles only 90 91 AD 2wd vehicles only 89 90 AD 4wd 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 space
32. 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 08 43 99 98 99 BR Central timer module software update when a wiper module is replaced 12 17 99 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 08 44 99 99 00 BR Intermittent speaker operation static 12 31 99 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 ENGINE TSB MODELS SUBJECT DESCRIPTION 09 04 99 98 99 BR Hard to diagnose noise coming from the engine turbocharger area 07 16 99 This bulletin applies to vehicles equipped with a Cummins 5 9L 24V diesel engine built prior to engine serial number ESN 56587424 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 A noise may be present which on initial investigation may sound like a noisy tur
33. of power Note See TSB 18 05 93 Engine rpm fluctuates when 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 number is higher than 44623028 the sensor is of the new design If the engine serial 17 CATEGORY 19 STEERING TSB 19 02 05 B 11 3 95 19 01 94 1 28 94 19 04 94 6 3 94 19 03 93 4 16 93 19 02 91 4 22 91 MODELS 94 95 BR trucks with a build date prior to 1 1 95 94 BR 4x4 94 BR 89 93 AD 89 91 AD with four 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 intermediat
34. on The bulletin is issued for information only 24 08 94 94 BR A C evaporator odor 5 6 94 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 22 CATEGORY 24 AIR CONDITIONING Continued 24 17 94 91 93 AD A C evaporation freeze up or lack of cooling on cycling clutch of air conditioning system 11 18 94 94 95 BR 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 be 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 impo
35. on load Use 75W 90 GL 4 or 80W 90 GL 4 rated synthetic oil Often members will ask about the GL 4 rated Castrol synthetic gear lubri cant 75W 90 If the GL 4 classification is good shouldn t a GL 5 rated lubricant be better In the case of the NV4500 gearbox not necessarily so The GL 5 oil uses twice the amount of sulfur phosphorous additive package as GL 4 At high temperatures the phosphorous plates out and re duces the coefficient of friction of the synchronizer rings New Venture Gear has seen this on shift stand tests Since there s twice as much of it there s more of a detrimental effect compared to GL 4 Although it does not affect the NV4500 the additional sul phur content of GL 5 attacks brass Six Speed NV5600 Manual Transmission This transmis sion is filled with manual transmission fluid at the factory This fluid does not require periodic changing If it is neces sary to add or change the fluid in this transmission use Mopar manual transmission fluid Mopar P N 4874464 or Texaco 1874 These are the only lubricants recommended for use in the NV 5600 transmission Axle oil Change every 30 50 thousand miles depending on load Use 75W 90 GL 5 rated synthetic oil for normal light to medium load duty cycle Tires Weekly check for proper air pressure with tires at ambient temperature Follow the Owner s Manual recom mendations for increasing pressure as load increases Front 45 55 Ibs Rear 40 80 Ibs
36. 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 CATEGORY 14 FUEL TSB MODELS SUBJECT DESCRIPTION 14 07 97 94 97 BR Diesel fuel injection pump tampering 7 18 97 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 throttle 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 CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS SUBJECT DESCRIPTION 18 25 97 96 97 BR EGR system failure with Hex Code 2E on 5 9L Diesel 8 15 97 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
37. or other jewelry while working on your vehicle Jewelry can scratch paint get caught in turning belts cause wiring short circuits and otherwise ruin your day e Keep your work area and tools clean neat and organized That way things will be easier to find when needed and safer to use e Wipe up floor spills before you slip and fall Keep tools free of grease and oil so your hands won t slip off e Place removed parts in a safe place so you won t trip over them while moving around the vehicle e Provide proper light for a better quality repair e Provide adequate ventilation if you are using chemicals or fuel as a solvent e Adequately support the vehicle on jack stands if you are working underneath it Use jacks and chains to support or move heavy loads e Never put a tool back in the toolbox without first cleaning it to be ready for the next use VEHICLE TRIM If your pickup has a top over the bed wedge a section of foam pipe insulation across the bottom of the bed where the tailgate closes against the bed This will keep most dust and water out of the bed interior If you install carpet remnants in your cab or truck bed you ll soon find that the cut edges will fray To keep the edges looking neat lay the carpet on a concrete floor lay a piece of metal 1 8 inch from the edge then heat the carpet edge with a propane torch Use care not to get the carpet too hot as you simply want to melt the synthetic fibers enough to
38. 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 56T13 59T6 There is no change to the JTEC PCM software CATEGORY 19 STEERING TSB MODELS SUBJECT DESCRIPTION 19 04 00 94 00 BR Squeaking creaking sound in steering column while turning 06 09 00 This bulletin applies to vehicles equipped with non tilt steering columns A squeaking creaking sound may be heard coming from the area 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 SUBJECT DESCRIPTION 21 02 00 99 00 BR 47RE transmission delayed upshift or no TCC engagement between 30 and 50 MPH 03 10 00 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
39. position The shop should then refer to the appropriate 97 Service Manual for proper diagnosis of the starter motor s electrical circuit 2 wo CATEGORY 8 ELECTRICAL Continued 08 22 97A 96 97 BR Inoperative speed control 7 11 97 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 determine the cause of the inoperative speed control Perform the repair as outlined in the bulletin 08 27 97A 97 BR Inoperative CD player as a part of sales code RAZ radio 9 26 97 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 08 30 97 98 BR Ashtray receiver lamp degrades from blue green to bright white 9 5 97 The ash receiver lamp when illuminated may change from a blue green illumination to a bright white illumination This chan
40. 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 same index system categories as DaimlerChrysler Below are the index categories 2 Front Suspension 14 Fuel 3 Rear Axle 16 Propeller Shafts amp U Joints 5 Brakes 18 Vehicle Performance 6 Clutch 19 Steering 7 Cooling 21 Transmissions 8 Electrical 22 Wheels amp Tires 9 Engine 23 Body 11 Exhaust 24 Air Conditioning 13 Frame amp Bumpers 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
41. replace the shift linkage with revised parts CATEGORY 23 BODY TSB MODELS SUBJECT DESCRIPTION 23 03 00 00 BR Vehicle Identification Number VIN Plate Relocated 02 04 00 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 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 23 19 00 94 01 BR Instrument panel creak 05 05 00 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 23 25 00 97 01 BR Paint fogging whitening 06 30 00 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 da
42. research to find which models and options are required to tow the intended weight then stick to inspecting trucks which meet those criteria Your familiarization session will lead you to ask the right questions when you visit the dealer lot or make contact with private sellers Next check the used vehicle value guides Most banks and other agencies that make car loans will have a variety of used vehicle value guides such as the Kelly Blue Book or NADA book that list wholesale retail and loan values for each model each accessory and offer mileage compensation factors These books are filled with option facts and regional pricing so can serve as a useful guide to true worth For those with a computer walk your fingers across a computer keyboard and visit the various web sites that offer needed information These include Kelly Blue Book kbb com NADA used truck guide NADA com carprice com edmunds com and others The dot com sites often track actual prices paid for trucks in your area or ina nearby metropolitan area If you want to research a particular truck web sites exist that allow you to check a particular serial numbered truck for lost stolen totaled reconstructed etc titles carfax com for a nominal fee You can also determine if a vehicle has been included in federal safety recalls by visiting several other sites Mining information from the web can be rewarding though time consuming but the more thorough your researc
43. screening in front of the truck s radiator is strongly recommended With three radiators engine cooling air to air intercooler air conditioning condenser it is important to have maximum airflow and minimum clogging due to bugs chaff and dirt The screen should also stop radiator penetration by rocks 9 ENGINE When changing the serpentine accessory drive belt always check the idler tensioner pulley to make sure its bearing is good The belt change interval is every 100 000 miles The turbocharger to intercooler to intake manifold piping clamps can come loose causing loss of turbo boost Check all rubber boots and clamps periodically for boot slippage under the clamps particularly if a loss of performance or a whistling noise is noticed while the engine is under load Periodically inspect the engine water pump bearing for leakage If any coolant is seen to drip or weep from the pump shaft area replace the pump before it fails 14 FUEL Trucks using an aftermarket remote mounted fuel filter have experienced abrasion of one or both hoses where they have contacted engine parts other underhood parts or each other Cover both lines with convoluted loom or rubber hose and route them in such a manner that they don t touch anything A few 97 trucks equipped with the remote mounted aftermarket Prime Loc fuel filter have experienced cracking of the bolt which holds the adapter to the Cummins fuel filter mount boss Thi
44. strut resulting in incomplete release of the band A washer is installed to prevent contact Speedometer drive gear replacement procedure An information only brochure to supplement the service manual 19 CATEGORY 22 WHEELS amp TIRES TSB 22 03 95 3 3 95 22 04 95 4 7 95 22 05 95 A 6 30 95 22 06 95 6 16 95 22 03 94 6 24 94 22 05 93 7 16 93 22 02 92 4 6 92 MODELS 95 BR 94 95 BR 94 95 BR with code WDC wheels 95 BR 94 BR 93 AD 89 92 AD CATEGORY 23 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 f
45. the door jambs A clean door jamb typically indicates a vehicle that has been fanatically maintained Wear should be commensurate with mileage Look underneath the body for caked mud and dirt This indicates off road operation or an unintentional trip into the ditch Look under the hood Lots of dirt can indicate severe use and little maintenance Check for worn or chafed hoses oil leaks coolant leaks etc Pull the dipsticks and check fluid colors and condition Sight down the body sides to see if the panels are smooth If they re wavy the truck has been wrecked and further inspection underneath will reveal the severity of the accident Paint color differences between panels and or variations in body seam gaps also indicate a wreck in the truck s past Inspect tires for uneven wear to determine if there are suspension or axle problems This can also be an indicator of improperly repaired wreck damage Look for lube drips from the underside of the engine transmission and axles Seal repairs may have to be made A light oil drip or evidence of misting near the engine road draft tube is normal Look in the glove box and console to see if any maintenance receipts or records have been left behind and compare them with what you see Go for a ride and note if the engine idles smoothly and pulls strongly Do the transmission and clutch work as intended Does the automatic transmission shift without slipping or hanging between gears
46. then spin the filter off and let it drop into the bag Zip up the bag No mess and it is then easy to remove the filter from its crowded location will note however if your engine is hot you may need to work fast or the filter could melt through the bag Justin Kirchhoft Another method is to drain the filter first by punching a small hole in its bottom before removing it Dave Lewis and James Johnson 14 FUEL In model years 94 through 98 the engines are equipped with a plunger type fuel transfer pump with a button type primer It is hard to locate and see the plunger button to prime the fuel system Paint the end of the plunger with a bit of white paint for greater visibility Jim Anderson With the introduction of the second generation trucks in 94 many members adapted to the decreased clearance problems in removing and replacing the fuel filter by using a filter strap wrench with a socket extension to remove the old fuel filter The procedure is to disconnect the water sensor wire thread the strap wrench under the wire and the drain tube onto the filter near the top tighten the wrench strapping and loosen the filter It is then spun off and removed by hand Prime the new filter with clean fuel before installing it TDR member Earl Kenney cautions us about diesel fuel storage Fuel stored in cans can collect water that may produce gels Fuel stored for long periods in cans coated with galvanizing or zinc will liberate a
47. transmission lines Automatic transmission cold temperature cooler bypass kit The condition occurs at ambient temperatures of 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 Th
48. trim panel retainer clips are separated from the door without using a trim panel removing tool 23 37 98 98 99 BR Cargo net eliminated from production 8 21 98 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 23 58 98 99 BR Wind noise whistle around grill area and or dimples on the grill painted surface opposite of the 11 27 98 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 TSB s Issued During 99 CATEGORY 2 FRONT SUSPENSION TSB MODEL SUBJECT DESCRIPTION 02 06 99 94 00 BR Front wheel bearing grease is evident on the bearing seal area Rev A This bulletin supersedes TSB 02 06 99 dated June 11 1999 The revisions include the addition 12 17 99 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 bearings includes a slightly greater amount of grease than is required for the beari
49. up and or MIL P1740 TCC or O D solenoid performance 11 12 99 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 CATEGORY 23 BODY TSB MODELS SUBJECT DESCRIPTION 23 08 99 94 99 BR Instrument panel creak 03 05 99 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 23 18 99 98 99 BR Bezel comes loose from seat bel
50. your engine has less than 10 000 miles on it Engine Fuel Filter Fill the fuel filter with fuel before instal lation and purge all air from the fuel system before starting the engine Issue 25 page 84 has the details on a 24 valve fuel filter change Change Intervals Change your engine oil and oil filter ac cording to the chart in your Owner s Manual Change the fuel filter at every other oil change Neither Dodge nor Cum mins recommends using extended drain intervals with the use of synthetic engine oils Change transmission and axle fluids according to the types of service listed in your Owner s Manual Anti freeze Coolant Drain and refill every 24 to 36 months using low silicate diesel rated ethylene glycol based cool ant Pre mix half and half with distilled water before instal lation or addition Automatic Transmission fluid Change fluid and filter every 40 000 miles for normal operation For operation such as towing or heavy loads change every 15 20 thousand miles The latest Mopar specification is ATF 4 type 7176 The latest ATF 4 can safely be used in all previous 47 RE RH automatic transmissions In this case logic prevails if 3 is good then 4 is better This information was veri fied by D C s customer advocate personnel If you have any doubts about the correct transmission fluid consult your Owner s Manual Five Speed NV4500 Manual Transmission Change every 30 50 thousand miles depending
51. 00 5th overdrive Four speed automatic 47RE 4th overdrive with locking converter This is a new electronically controlled transmission Maximum Tow Ratings 2500 regular cab manual or automatic 3 54 axle 10 500 pounds 16 000 GCWR 2500 regular cab manual or automatic 4 10 axle 12 300 pounds 18 000 GCWR Derate trailer weight for 4x4 3 54 axle 500 pounds 4 10 axle 400 pounds Derate trailer weight for extended cab 0 3500 regular cab manual or automatic 3 54 axle 10 500 pounds 16 000 GCWR 3500 regular cab manual or automatic 4 10 axle 11 900 pounds 18 000 GCWR Derate trailer weight for 4x4 3 54 axle ratio 800 pounds 4 10 axle 400 pounds Derate trailer weight for extended cab 3 54 ratio 800 4 10 ratio 400 pounds Cab Chassis models Available in regular cab only 2500 is 8 800 GVWR 56 C A cab rear to rear axle centerline dimension 3500 is 11 000 GVWR and available in 60 and 84 C A dimensions Comments Trailer tow ratings begin to get confusing Lazy performance complaints stem from computer programming of new electronically controlled automatic transmission Exhaust Gas Recirculation added to California trucks 1 1 96 to meet CARB emissions standards Owners begin to find out how easy and inexpensive it is to turn up the power 1997 Turbo Diesel What is New Hydraulic power brake booster powered from power steering pump Increased weight capacity to 11 000 GVW on club cab
52. 1 94 95 BR Tailgate latch handle loose 10 7 94 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 23 73 94 94 BR Cup holder rattle 10 7 94 If cup holder rattles in the closed position add a foam block to the back of the mug holder 23 95 94 A 94 95 BR Front seat cover wear through above the recliner pivot 12 30 94 The condition is wear through at the recliner pivot Inspect as directed and repair if necessary 23 98 94 94 BR Tailgate hard to latch in cold temperatures 12 23 94 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 21 CATEGORY 23 BODY Continued 23 101 94 94 95 BR Anti friction tape on A pillar 12 30 94 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 not remove the anti friction tape 23 57 93 94 BR Instrument panel creak 10 8 93 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
53. 3 governor pressure sensor volts too high 04 30 99 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 or CATEGORY 18 VEHICLE PERFORMANCE Continued 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 transmission 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 18 08 99 98 99 BR Improved speed control system sensitivity to set speed 04 30 99 Some customers may complain that their vehicle speed control system may be too busy or drift more than 2 m
54. 3500 models Remote keyless illuminated entry option New AM FM Cassette CD player option Leather interior group option Models Available 2500HD as standard cab extended cab long bed cab chassis 4x2 and 4x4 Combo of short box extended cab diesel not offered 3500 Same as above No short bed models available Engine Ratings Same as 1996 model year 215 HP and 440 ft lbs for manual transmission 180 HP and 420 ft lbs for automatic transmission California engines continue with EGR but are offered with 180 HP and 420 ft lbs of torque in both automatic and manual transmission applications Transmissions No changes from 1996 Five speed manual NV4500HD 5th overdrive Four speed automatic 47RE 4th overdrive with locking converter Maximum Tow Ratings 2500 manual 4x2 regular and extended cabs 20 000 GCWR 2500 automatic 4x2 regular and extended cab 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR 2500 manual and automatic 4x4 regular and club cabs 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR 3500 manual 4x2 regular and extended cabs 20 000 GCWR 3500 automatic 4x2 regular and extended cab 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR 3500 manual 4x4 regular and extended cabs 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR 3500 automatic 4x4 regular and extended cabs Regular cab same as above Extended cab 4 10 axle only 18 000 GCWR 3 54 ratio not available with extended cab automatic option Cab Cha
55. 406 05015090AA 2001 3942470 3937145 3097074 5080810 52028715 3954194 FS19579 LF3959 LF3894 AF25541 52006482AB 05015581AA 05016547AB 4728406 05015090AA 2000 3942470 3937145 3097074 5080810 52028715 3954194 FS19579 LF3959 LF3894 AF25541 52006482AB 04883963AB 05016547AB 4728406 05015090AA 99 3931476 3937145 3097074 5080810 52028715 3954194 FS19528 LF3959 LF3894 AF25541 52006482AB a8 04883963AB 05016547AB 4728406 05015090AA 24wae onale 3931476 3937145 3097074 5080810 52028715 3954194 FS19528 LF3959 LF3894 AF25541 52006482AB ee 04883963AB_ 05016547AA 4728406 05014568AA jamais ondine 3931476 3932217 3865405 3097074 5080810 71715 3934373 FS19528 LF3349 LF3552 AF25541 71716 04883963AB_ 05016547AA 4728406 05014568AA 97 3931476 3932217 3865405 3097074 5080810 71715 3934373 FS19528 LF3349 LF3552 AF25541 71716 4741689 05016547AA 4728406 05014568AA 96 3923108 3932217 3865405 3097074 5080810 71715 3934373 FS1253 LF3349 LF3552 AF25541 71716 4741689 05016547AA 4728406 05014568AA 95 3923108 3932217 3865405 3097074 5080810 71715 3934373 FS1253 LF3349 LF3552 AF25541 71716 4741689 05016547AA 4728406 05014568AA 94 3923108 3932217 3865405 3097074 5080810 71715 3934373 FS1253 LF3349 LF3552 AF25541 71716 4429107 05016547AA 4713953 44420970 93 3834656 3932217 3865405 3097073 5080830 71594 3802273 FS1232 LF3349 LF3552 AF25023 71595 4429107 05016547AA 4428308 44420970 92 3834656 3932217 3865405 3097072 5080830 71594 3802273 FS1232 LF3349 LF3552 AF4555
56. 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 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
57. CATEGORY 25 EMISSIONS TSB MODELS SUBJECT DESCRIPTION 25 001 01 01 BR BE Generic Scan Tool May Not Display Certain DTC s and Erroneous LDP Switch 1 19 01 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 25 002 01 01 BR BE Scan Tool Erroneously Displays P000 For DTC s P1740 And P0461 1 19 01 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 52 RECALL NOTICES 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 Posi
58. M 71595 i 4429107 05016547AA 4428308 44420970 ha en 3834656 3932217 3865405 3097072 5080830 71594 3802273 FS1232 LF3349 LF3552 AF4555M 71595 5i 4429107 05016547AA 4428308 44420970 EAA 3834656 3932217 3865405 3097072 5080820 70540 3802273 FS1232 LF3349 LF3552 AF4555M 71530 4429107 05016547AA 4428308 44420970 90 3834656 3932217 3865405 3097072 5080820 70540 3802273 FS1232 LF3349 LF3552 AF4555M 71530 4429107 05016547AA 4428308 44420970 89 3834656 3932217 3865405 3097072 5080820 70540 3802273 FS1232 LF3349 LF3552 AF4555M 71530 63
59. N Diagnosing oil consumption The concern is an operator report of greater than one quart per one thousand miles Variations in oil level are likely possible 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 SUBJECT DESCRIPTION 11 03 94 94 BR Diesel
60. ab Revised paint schemes and colors Models Available 2500HD as standard cab extended cab long bed 4x2 and 4x4 3500 same as above Engine Ratings Same sas 1994 model year 175 HP and 420 ft lbs for manual transmission 160 HP and 400 ft lbs for automatic transmission Transmissions No changes from 1994 Five speed manual 4500HD 5th overdrive Four speed automatic 47RH 4th overdrive with locking converter Maximum Tow Ratings 2500 and 3500 3 54 Axle maximum GCWR is 14 100 pounds 4 10 Axle maximum GCWR is 16 000 pounds Cab Chassis Models None Comments The 1995 model is largely a carryover from the 1994 model year with the exception of the introduction of the extended cab 1996 Turbo Diesel What is New Deleted tailgate top protector Deleted SLT tape stripe Added optional Camper suspension package Revised optional radio Revised alternator rating to 136 amps Revised RE electronic control of automatic transmission Models Available 2500HD as standard cab extended cab long bed cab chassis 4x2 and 4x4 3500 same as above No short bed models available Engine Ratings Increased for 1996 215 HP and 440 ft lbs for manual transmission 180 HP and 420 ft lbs for automatic transmission California engines were rated lower at 1995 specs At mid year 1996 California engines were required to have exhaust gas recirculation EGR Transmissions Five speed manual NV45
61. action cycles of the exhaust manifold ES CATEGORY 9 ENGINE Continued 09 001 01 01 Intermittent loss of oil pressure sensor ouput voltage 1 19 01 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 09 003 01 All Engine oil additives supplements 5 4 01 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 CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS SUBJECT DESCRIPTION 18 31 1 98 5 2002 BR BE Cold idle engine warming New Release This bulle
62. ad to the stiffening rib of the instrument panel to isolate the components 23 49 94 94 BR Warped tailgate 7 1 94 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 23 51 94 94 BR Tailgate rattle 7 1 94 If a tailgate rattle is heard inspect the tailgate pivot bracket Repair as described in bulletin with replacement stud and bearing mount 23 60 94 94 BR Popping or snapping noise from windshield 8 12 94 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 23 63 94 89 93 AD Cowl cracks 8 26 94 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 23 68 94 94 95 BR Glue seeps out at backlight or windshield moulding 9 30 94 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 23 7
63. ake sure it meets all criteria First on your to do list following a second general walk around inspection and a ride and drive session of a particular truck should be some research to find out who the former owner was and initiate a conversation If you re buying from a dealer ask the owner what the mileage was at turn in time and on what date the vehicle was turned in If the truck has been in a dealer s possession for a while has it been used for hauling chores with no maintenance Have other potential buyers shied away from it for some reason not readily evident Find out why Ask the former owner what maintenance has been performed and when and if the truck has been wrecked What was it used for Was it satisfactory for that use If the owner has maintenance records arrange to pick them up if you buy the truck Finishing Up You ve done the research negotiated the price and now it is time to exchange dollars for the vehicle The job s not done until the paperwork is finished and the paperwork had better be right If buying from a dealer you should receive a bill of sale and certification of the odometer reading along with several other pieces of paper which will vary by state Usually the dealer will apply for a new title in your name If buying from a private individual you should receive a clear title signed over to you by the owner You will then take the title to your vehicle registration place to get a new ti
64. arts 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 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 Anew kit has been released that will allow technicians to repair turbochargers with failed wastegate actuators 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 t
65. ate 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 5 an auxiliary steering damper 15 96 N a CATEGORY 19 STEERING TSB MODELS SUBJECT DESCRIPTION 21 04 96 96 BR Transmission will not upshift following a 3 2 downshift 3 15 96 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 overdrive is off The repair involves reprogramming the powertrain control module with new software 21 13 96 96 BR Transfer case shifter buzz or clatter 9 20 96 4x4 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 21 15 96 95 97 BR Quick connect removal and reconnect procedure 11 8 96 The information only bulletin describes the repair procedure for removal reconnect of the transmission cooler line
66. atings 175HP 420 ft lbs torque for manual transmissions and 160 400 for automatic transmissions New is an inline Bosch fuel injection pump designated P7100 Intake air plumbing has been re designed for greater airflow The turbocharger is a wastegated design Transmissions Five speed manual NV4500HD 5th overdrive 450 ft lbs input torque capacity Four speed automatic 47RH 4th overdrive with locking converter 380 ft lbs torque capacity Looking Back Being an all new model this truck had a number of teething problems which resulted in both federal safety recalls and factory TSB fixes Chief among recalls was a fix for keys sticking in the backside of the steering wheel causing the wheel to jam recalls for various covers to be installed on steering shaft linkages and headlight switches burning out Major owner gripes centered around poor fuel filter and oil filter access moisture intrusion and retention into cab and cab doors vision obstruction by the A pillars poor adhesion of certain colors of paint failure of the OEM Goodyear tires to maintain their balance loss of fifth gear in the manual transmissions fraying of the unsheathed throttle cable Conclusions These trucks have proven to be very durable though not particularly good looking after several years of use Owners have reported driving them in excess of one million miles without any major internal engine work 1995 Turbo Diesel What is New Extended c
67. ation 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 wonder if this repowered truck has any TSBs The truck is a 1947 custom built Dodge 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 manufactured 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
68. ator 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 18 24 99 00 BR 5 9L 24V Cummins diesel low power or poor performance diagnostic 11 15 99 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 41 CATEGORY 18 VEHICLE PERFORMANCE Continued 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 co
69. bocharger 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 CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS SUBJECT DESCRIPTION 18 02 99 98 99 BR Erratic torque converter clutch TCC operation 02 19 99 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 TPS or Alternator This bulletin involves selectively erasing and reprogramming the Powertrain Control Module PCM with new software calibration changes 98cal12 and 99cal14 18 07 99 98 99 BR Erroneous MIL illumination with DTC A8 P176
70. bushings or worn front suspension grease joints Groaning and other front suspension noises on 4x4 models built prior to 1994 can sometimes be traced to the universal joints at the outboard axle ends of 4x4 models A simple test is to engage the manual locking hubs and drive the vehicle If the noise disappears replace one or both joints On 4x4 models a front end shimmy may be caused by a worn steering stabilizer unit This horizontally mounted shock absorber should be periodically replaced as a wear out item This problem appears more frequently on trucks equipped with aftermarket tires and rims of a larger than standard size During servicing don t forget to check the fluid level in the power steering pump It is located low on the driver s side of the engine near the front in a location covered by hoses and wires 21 TRANSMISSIONS The cooling lines for automatic transmissions can have a point of close contact with each other where they cross near the bellhousing A piece of convoluted loom or rubber hose placed on one of the lines will prevent chafing and wearing through of the metal tubing All trucks built prior to 1998 5 and equipped with the NV 4500 five speed manual transmission have a problem with fifth gear coming unpinned from the mainshaft A revised nut and crush washer have been developed to cure this problem along with a 14 page Dodge Factory Tech Service Bulletin outlining the proper repair procedure
71. c trucks and faulty fuel level sending units Common Problem areas 1998 5 to current Included failed fuel transfer pumps and fuel injection pumps weak clutch on six speed trucks poor front brake pad life in certain applications and poor front suspension bushing life on 4x4 models FROM THE DATA BOOKS The following information was compiled using DaimlerChrysler data books Actual production may be slightly different especially if a particular truck was produced near the beginning or end of a particular model year run We will start with the 1994 model which is the first year of the current body style For each model year we will note what s new models available engine ratings transmissions maximum tow ratings cab chassis models and comments 1994 Dodge Turbo Diesel What is New Introduction of the current truck platform Everything is new Models offered 2500 and 3500 two wheel drive four wheel drive standard cab long bed only Cab Rather revolutionary styling which has since been emulated by other truck manufacturers Styling changes included protruding grille and hood Grille is attached to hood and raises with hood for improved underhood access Cab has aerodynamically correct shape Offered only as a standard cab long bed truck and as a cab chassis model Two trim levels ST in vinyl and SLT in cloth Cab features include redesigned dash with full gauges featuring numbered graduations All major cab co
72. chemical from the coating that can form harmful compounds resulting in hard crystalline deposits in the injector system Worried about being in the middle of nowhere and running out of fuel Cummins reminds us that the 12 valve B 5 9 engine will run on fuels besides 1 and 2 diesel and blends thereof Alternate fuels include 1 K and 2 K kerosene Jet A Jet A 1 JP 5 and JP 8 jet fuels Fuels not approved by Cummins are Jet B JP 4 and gasoline Cummins stipulates that alternative fuels must be used only in an emergency and that the engine runs best and most efficiently on 2 diesel fuel On 94 through 98 12 valve Cummins engines there is a fuel pre filter neater that most mechanics don t know about It is located between the fuel tank and the fuel transfer pump low on the engine left side near the rear The bottom bowl screws off and the plastic strainer screen should be cleaned periodically Don t forget to properly reseat the gasket before reinstalling the filter bowl Robert Patton If you damage or lose the fuel pre strainer gasket during servicing you have two alternatives Purchase a kit from Dodge for 27 00 which contains the gasket or go to an industrial rubber supply house and purchase a 2 3 4 x 3 x 1 8 rubber quad ring for less than 2 00 A perfect fit John Murry A card is available from Flying J truck stops which entitles you to a one cent per gallon fuel discount minimum 20 gallon purchase The card is
73. conditioning lines as you don t have to worry about tipping spilling oil EMERGENCY REPAIRS Emergency repair of small holes in a gas tank can be made by rubbing a bar of soap across the hole The leak will stop A permanent repair can be made using epoxy Emergency temporary repair of small radiator leaks can be made by putting in two or three egg whites Start the engine to circulate the coolant and get the egg to the hole Oatmeal or flour may also work An emergency repair for a hole punched in your oil pan is to round the hole with a punch then insert a rubber tire valve stem first into the hole Coat the valve with gasket cement if available Push or pound it home with a hammer IN THE TOOLBOX Plastic tie wraps are so handy almost everyone has them in the toolbox Keep them organized by hanging a bunch on a single tie then cut the head off the single tie Friction will keep them in place To get a new one just slide it off the end When cutting off old ties cut them near the back of the head so they can be used again for a smaller project Most tool kits contain both metric and standard wrenches Color code with paint or tape the wrenches of a certain type to make them easier to identify If your ratcheting socket wrench handle constantly bangs on nearby metal while in use slip a piece of rubber tubing over the handle end to cushion it If you want to magnetize a screwdriver or other tool stroke its tip with a magn
74. d 23 29 96 94 96 BR Tailgate cracking on top inner ends 5 10 96 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 23 45 96 94 96 BR Instrument panel creak 8 2 96 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 23 46 96 94 96 BR Rattle in door area 8 2 96 Inspect the area of the door latch face around the lower window channel retaining bolt If necessary perform the outlined repair procedure 27 CATEGORY 23 BODY Continued 23 69 96 97 BR Repair procedure for fallout damaged paint 11 22 96 Mopar Parts has released a new product Mopar Fallout Removal Kit p n 0488241 7 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 CATEGORY 24 AIR CONDITIONING TSB MODELS SUBJECT DESCRIPTION 124 01 96A 94 96 BR Heater A C s
75. duce 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 09 03 00 00 BR Engine oil seepage past the oil fill cap on 5 9L 24V diesel engine 02 18 00 This bulletin applies to vehicles equipped with a 5 9L 24V diesel engine built before engine serial number 56664950 with a date 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 45 CATEGORY 14 FUEL TSB MODELS SUBJECT DESCRIPTION 14 01 00 00 BR Thump bump sound heard 1 3 seconds after
76. e 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 CATEGORY 8 ELECTRICAL Continued 08 17 00 99 00 BR Intermittent speaker operation static 05 12 00 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 08 18 00 98 01 BR Radio Interference to from two way radio receivers 05 12 00 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 08 23 00 98 01 BR Plastic boot to protect the electrical harness B end terminal at the generator 06 23 00 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
77. e information only bulletin describes the replacement of the 5th gear main shaft nut with a new nut if the original nut has to be removed Under no circumstances is the original part to be reused Special Mopar lock seal should be applied to the threads at reassembly CATEGORY 21 TRANSMISSION Continued 21 11 95 7 7 95 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 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 Overdrive unavailable in extreme cold temperatures The information only bulletin emphasizes a change to the PCM for 1996 For 96 in ammbient temperatures of 5 F and be
78. e shaft is described Slow steering return The bulletin applies to 4x4 trucks with a Dana 60 axle 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 on 04778524 may be used Steering Column coupler A repair 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 21 02 95 3 31 95 21 03 95 A 6 16 95 21 04 95 4 14 95 21 05 95 A 1 5 96 21 08 95 1 30 95 21 09 95 6 30 95 MODELS 95 BR built after 3 20 95 94 95 BR 94 95 BR trucks with automatic transmission 94 95 BR trucks with automatic transmission 94 95 BR 94 95 BR trucks 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
79. ead the oil level accurately Steve Richards Use a Sidewinder ratchet wrench available at many chain auto parts stores for fuel filter removal with a strap wrench The Sidewinder also keeps your hands clean when removing the oil pan drain plug Barely loosen the plug with a standard 3 8 drive ratchet then switch to the sidewinder and twist the T handle to avoid having hot oil run down your arm as the plug is loosened Edmund Turner Jr An easy and clean way to drain the engine oil is to loosen but not remove the drain plug Oil will come out of the pan through grooves cut in pan sides if the plug is loosened by more than two turns Then you don t have to fish in the drain pan for the plug and gasket Louis Barnhart Oil changes become even simpler and cleaner with the addition of an inexpensive accessory called the EZ change drain plug which replaces the standard drain plug By screwing on a special hose adapter at drain time the plug s drain valve automatically opens and the draining oil is directed through a hose to the drain pan Removing the drain tube reseals the plug The plug kit is available from Geno s Garage Call 1 800 755 1715 A way to loosen a tight oil filter or canister type fuel filter is to take a long flat blade screwdriver place it on the filter rim at the proper angle and strike it several times with a hammer to drive the filter in a counter clockwise direction Louis Sytsma It is easier
80. easier and neater put on a pair of surgical gloves They improve your grip and keep your hands clean When the filter is off the vehicle simply hold the filter top with one hand and with the other pull the glove off your hand by turning it inside out over the top of the filter Then oil can t get out of the filter opening A commonsense reminder before installing a new oil or fuel filter write the date and mileage on the filter with a marker to make remembering these vital details easier Also before installing a new oil filter or a new diesel fuel filter prime it with the appropriate fluid first Get the filter as full as possible Have you found yourself with a difficult to remove oil filter You tried with no avail the band wrench strap wrench and filter claw tool that you found at the auto parts store You tried the screwdriver through the side of the filter trick only to have the screwdriver twist in place Your last re sort try a hammer and chisel to the top edge of the filter housing Oh yeah be sure to knock the chisel in the counter clock wise direction as viewed from the bottom of the filter Best ever filter removal tip once the filter is moved from its tool tight position to a hand tight removal place a large freezer bag around the filter Now when it drops from the housing extra fluid simply spills into the bag and not on the floor Additionally it is easy to retrieve the bag filter from around the air
81. effort If the truck has a Mopar aftermarket speed control kit the kit already has the revised parts 14 01 89 89 AD Injection pump diagnosis procedure 10 2 89 A troubleshooting procedure is outlined to help diagnose diesel engine problems CATEGORY 16 PROPELLER SHAFTS amp U j OINTS TSB MODELS SUBJECT DESCRIPTION 16 02 95 94 95 BR Droaning noise vibration 11 3 95 automatic The symptom condition is a droaning type noise and or vibration felt in seat track floor pan or transmission trucks 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 rom on 4x4 models with torque converter clutch engaged The repair involves replacement of the propeller shaft 16 01 94 94 95 BR Shudder at start on vehicles with two piece driveshafts operated at near maximum GVW 10 14 94 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 CATEGORY 18 VEHICLE PERFORMANCE TSB 18 29 95 A 10 16 95 18 01 94 1 14 94 18 10 94 A 7 29 94 18 05 93 4 30 93 18 06 92 A 7 23 93 18 05 92 6 15 92 18 06 92
82. el 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 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 Ww 4 CATEGORY 8 ELECTRICAL
83. ember 3 1999 This bulletin 10 01 99 identifies the parts and labor operation numbers necessary to install a child seat tether anchor 43 TSB s Issued During 00 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 the 05 12 00 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 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
84. 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 21 04 00 96 99 BR Erroneous MIL illumination for P1763 Transmission Governor Pressure Sensor Volts Too High 06 30 00 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 third 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 CATEGORY 21 TRANSMISSION Continued This b
85. et If you want to demagnetize a tool run the shaft or tip between the electrode arms of a soldering gun while it is turned on Slip a tube of closed cell foam pipe insulation over your floor jack handle to keep it from damaging the paint on the body sides of your ride Leave the top of the handle clear for a good grip Make an old dental pick a part of your toolbox It has many uses such as picking up small parts scraping gasket material out of tight corners cleaning grease out of cracks and aiding in assembly of small parts Cleaning up your tools after a project is fast and easy with this tip Spray them with carb cleaner and then wipe them dry and clean before putting them away THRU THE LOOKING GLASS If your wiper blades streak the windshield or otherwise act as if they are worn out don t replace them Just sand them That s right run a block with wet 600 grit paper along the rubber wiper edge for a few strokes to remove the small cut places in the blades and they ll work like new If your windshield is badly streaked from worn out blades polish out the streaks with toothpaste Apply to a damp cloth and wipe back and forth across the affected area applying moderate pressure Rinse off the residue when finished CLEAN YOUR RIDE An easy to make bug scrubber that won t scratch paint can be made by wadding several pairs of old panty hose together and using it as a wet sponge This also works to remove tar from chro
86. exhaust stains 5 13 94 The bulletin applies to 5 speed trucks built prior to 2 1 94 and automatic 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 11 02 92 88 92 AD Rear tailpipe support bracket cracking 7 27 92 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 CATEGORY 14 FUEL TSB MODELS SUBJECT DESCRIPTION 14 05 94 94 BR Use of low sulfur fuel 4 8 94 89 93 AD 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 14 15 93 89 93 AD 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 14 02 90 89 90 AD Accelerator pedal effort too high 12 3 90 The bulletin describes the installation of revised parts to lessen the pedal
87. fer 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 engine 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 dea
88. ge will occur over a long period of time of continuous use This bulletin involves replacing the ash receiver lamp and housing with revised parts 08 32 97 94 98 BR NHTSA authorized airbag deactivation for medical necessity 9 19 97 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 08 35 97 98 BR Dead battery from ignition off draw IOD 9 26 97 The problem described is a dead battery due to the glove box lamp remaining illuminated when the glove box 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 08 39 97 98 BR Remote keyless entry transmitter batteries discharge prematurely 11 28 97 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 CATEGORY 11 EXHAUST TSB MODELS SUBJECT DESCRIPTION 11 01 97 94 97 BR Whine or howl while driving at highway speeds 5 16 97 This bulletin applies to vehicles equipped with the diesel engine
89. h at this stage the more informed you will become as a buyer Now is also the time to make a call to your automobile insurance agent for a rate quote to make sure there are no after the purchase unpleasant surprises in this part of truck ownership If you plan to get a loan for the vehicle now is also a good time to shop around for the best interest rate and payment plans and to get approval for the loan It is as important to shop for the cost of money as it is to negotiate a good price for the truck After you have done your research then it is finally time to go looking for just the right truck You now have a pretty good idea of what you want what you might have to pay and how you re going to pay for it My advice is to buy the latest model truck with the lowest mileage that you can afford The newer the truck the lower the maintenance and repair costs are likely to be over time Look for a well maintained cream puff They re out there but it is up to you to find them Inspection Time In looking at a used vehicle don t be dazzled by surface shine Look behind the shine to uncover a vehicle s true condition Look at the truck s overall cleanliness There is a difference in appearance between a good cleanup job and continuous regular cleaning over the truck s life to the present Look at the interior for worn carpets and upholstery The editor s favorite place to check for attention to detail cleanliness
90. he replacement filter is part number 04883963AB Cummins 3931476 Fleetguard FS19528 14 04 98 98 BR Accelerator pedal 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 Ww 6 CATEGORY 21 TRANSMISSION TSB MODELS SUBJECT DESCRIPTION 21 10 98 94 99 BR Loss of fifth gear Rev A This bulletin supersedes technical service bulletin 21 10 98 with an effective date of September 9 25 98 11 1998 This bulletin applies to vehicles equipped with a NV 4500 manual trans
91. hrottle 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 CATEGORY 6 CLUTCH Continued 06 01 90 A 89 91 AD with Transmission noise below 1400 rpm 12 31 90 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 or durability related The diagnosis involves a road test to pinpoint the rom at which the noise occurs The revision involves a change of the flywheel CATEGORY 7 COOLING TSB MODELS SUBJECT DESCRIPTION 07 04 94 94 BR Service manual revision thermostat seals 4 8 94 Revised service manual pages showing t stat seal pictures 07 07 94 94 95 BR Engine slow to warm up in cold ambient temperatures 9 30 94 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 07 01 91 89 90 AD Overheating or no heat condition 1 28 91 An interference between the thermostat and c
92. ian 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 08 23 96 94 96 BR Clicking noise from speedometer 8 23 96 built prior to 12 15 96 If a clicking ticking noise is heard coming from the instrument cluster area the bulletin describes the repair procedure to replace the speedometer 08 33 96 94 97 BR Trailer tow wiring information 10 11 96 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 08 47 96 97 BR Radio interference from buzzer module 12 20 96 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 25 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 bulle
93. ile 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 timing gear housing 46 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
94. ine Control Module ECM software corrects this condition calibration change 99CalT9A CATEGORY 19 STEERING TSB MODELS SUBJECT DESCRIPTION 19 03 99 94 99 BR Steering slow to return to center 05 07 99 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 19 04 99 99 BR Steering system diagnosis 05 28 99 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 perform as designed CATEGORY 21 TRANSMISSION TSB MODELS SUBJECT DESCRIPTION 21 08 99 96 99 BR Buzz whine or moaning type noise from a cold transmission when reverse is selected 04 30 99 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
95. ish soap until the residue is gone 23 22 97 94 97 BR Driver s side wiper blade contacts A Pillar 4 4 97 This bulletin applies to vehicles built before Oct 15 1996 If the driver s side wiper blade contacts A Pillar or a popping sound 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 23 25 97 96 97 BR Windnoise whistle around grille area 5 2 97 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 23 27 97 94 97 BR Water leaking through rear window 5 9 97 The problem is water leaking past rear window module into cab of vehicle The bulletin outlines the repair procedure 23 39 97 94 97 BR Driver side power mirror vibrates while driving 6 27 97 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 po
96. l still be necessary to set the variance of the compass prior to vehicle retail delivery 08 22 99 98 BR Intermittent operation of oil pressure gauge 07 02 99 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 08 28 99 00 BR Simplified compass mini trip computer calibration 08 20 99 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 08 32 99 98 99 BR Radio interference to from two way radio receivers 10 01 99 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
97. ld be installed Interior film build up on windows Window film build up is caused 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 CATEGORY 23 BODY Continued 23 36 94 94 BR Front door to windshield moulding squeak creak 4 22 94 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 23 39 94 94 BR Pickup box floor rattle 5 6 94 The bulletin involves applying sealer to the pickup box floor at the crossmember 23 40 94 A 94 BR Door glass rattle 5 6 94 If the door glass rattles when the door is closed and the window is open the bulletin describes the diagnosis and repair of the weather strips 23 41 94 94 BR Creak noise from instrument panel bezel 5 13 94 If a creaking noise occurs coming from the instrument panel bezel add felt tape to dash to dampen isolate the components 23 45 94 94 BR Snapping noise at right side of instrument panel 6 3 94 A snapping noise sounds like a small stone hitting the window may occur If diagnosed add a p
98. ler 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 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 stretch 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 deform
99. low the PCM inhibits the transmission from shifting 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 shif
100. me trim Tired of getting spray tire dressing all over your newly cleaned wheels Make a cardboard template to hold over the rims and spray away It is likely you already have a great tar remover in your toolbox Spray WD 40 on the tar let it sit then wipe the tar off It won t hurt the paint either If you want the interior of your ride to always smell fresh and clean lay a bar of Irish Spring soap under the seat If you want a different scent a sheet of fabric softener works too Your truck is washed and it is time to dry it Before you break out the towels chamois let s play a litlle bit longer and put the water to work drying the vehicle Say what Follow the procedure Remove the spray nozzle from the hose Starting at the roof let the steady stream of water collect the drops and flow them off the surface Move to the windshield hood windows doors cargo box tailgate The stream of water does a great job of drying your truck Fin ish off the job with your towel CLEAN YOURSELF A good way to clean your hands after a dirty job is to use soap and used coffee grounds Just put some of each in your hand add water and then scrub till your hands are clean BODY WORK When sanding inside curves wrap sandpaper around an old piece of radiator hose or other thick walled hose of the correct diameter You ll get a smooth material removal Planning to put a wild paint scheme or set of stripes on your truck but y
101. mended Poor AM radio reception Proper review of the condition with vehicle operator is Tighten the antenna base to 70 in lbs to assure reception Infinity radio code RAY looses sound 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 eq
102. ment cluster through the odometer reset button hole He installed a small O ring on the button shaft and now keeps a clean instrument cluster If your shoulder seat belt buckle rattles against interior trim while driving install a small piece of velcro on the back of the seat belt buckle trim where the buckle hits the trim With the velcro the buckle will stay in place Robert Patton To remove bugs from the grille area fill a spray bottle with one part diesel fuel one part water and a small amount of detergent Shake well and apply let it sit then hose it off Tom Clayton Four wheel drive 2500 series Dodge trucks come with plastic rear wheel well liners as standard while two wheel drive trucks do not The four wheel drive liners can be used on two wheel drive trucks with no modifications They are available through Dodge parts for about 60 00 per set The liners make cleaning easier and prevent mud and salt buildup in the fenderwells Do your outside rearview mirrors jiggle when going down the road For trucks equipped with an aftermarket wind deflector bugshield start your troubleshooting by removing it The same advice applies if your radio antenna whips about violently 24 AIR CONDITIONING Spray a disinfectant such as Lysol into the A C vents occasionally to kill mold and odors 26 MISCELLANEOUS Here are several cleaning tips After washing your truck give it a final rinse using water from the hose without the
103. mission and the 8 0L V10 gas engine or the 5 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 CATEGORY 23 BODY TSB MODELS SUBJECT DESCRIPTION 23 13 98 98 BR Rear sliding window difficult to open will not remain latched and or leaks water past the lower 5 8 98 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 23 16 98 98 BR Splash guards mud flaps discolored and or distorted due to proximity to tailpipe 5 1 98 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 23 17 98 94 98 BR Center armrest driver side hinge cover broken 5 1 98 If the center armrest upper inertia latch cover driver side hinge cover is broken the proper repair involves replacement of the hinge 23 35 98 94 99 BR Door trim panel retainer clip attachment breakage when door trim panel is removed for service 8 7 98 The bulletin cautions the dealer that damage to the door trim panel may occur if the door
104. moldings from entire bed sides Deleted extended cab option leaving only the quad cab option Anti spin rear axle only available in 4 10 ratio Optional 265 75R 16E Michelins on 7 5 x 16 cast aluminum wheels for all 2500 models 3500 series standard tires are now LT235 85R 16E using steel wheels of greater offset Models Available 2500HD as standard cab quad cab short bed long bed cab chassis 4x2 and 4x4 3500 Same as above No short bed models available Engine Ratings Same as 98 5 99 model years 235HP 460 ft lbs torque for manual transmissions 215 HP 420 ft lbs torque for automatic transmissions Transmissions Five speed manual NV4500HD_ 5th overdrive Six speed manual NV5600 6th overdrive Four speed automatic 47RE 4th overdrive with locking converter The six speed manual transmission has the same first and overdrive ratios as the five speed with an additional ratio interposed between second and fourth gears Fifth gear is direct Maximum Tow Ratings 2500 regular cab and quad cab 4x2 both manual transmissions both axle ratios 20 000 GCWR 2500 regular cab and quad cab 4x4 both manual transmissions both axle ratios 20 000 GCWR with the exception of the quad cab 4x4 short bed 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR 2500 regular cab and quad cab 4x2 and 4x4 automatic 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR 3500 regular cab and quad cab 4x2 and 4x4 long bed both manual tra
105. n With automatic The symptom typically occurs at maximum load and is engine speed specific 1900 rpm for 4x2 transmission and 5 9 models 1850 rpm for 4x4 models with the truck in fourth gear and the torque converter clutch Turbo Diesel engine locked up If the problem is identified a repair procedure involving a revised propeller shaft with Note 96 2500 club a yoke weight damper is described cab 155 WB 4x4 with heavy duty transfer case built after 5 9 96 have the revised propeller shaft CATEGORY 5 BRAKES TSB MODELS SUBJECT DESCRIPTION 05 14 95 A 95 96 BR Brake pedal noise when depressed 2 9 96 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 05 02 96 A 94 97 BR Accelerated brake lining wear front versus rear 11 15 96 2500 8800 GVW The bulletin supersedes TSB 05 02 96 dated 2 23 96 The bulletin adds the 3500 series truck sales code and 3500 and incorporates the use of revised brake linings The bulletin discusses wear conditions The built before 8 5 96 repair procedure involves replacing possibly the front brake linings rear brake linings or rear wheel cylinders depending on truck model and vehicle sales code 05 08 96 94 96 BR Brake pedal rattle 9 13 96 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 re
106. nd therefore you may want to read from the start 1994 to see total changes and cumulative modifications for the particular model year you wish to research Each model year after 1994 contains changes in the form of additions and deletions to the previous model s Only major changes and major new options are covered As you know each year contains changes to paint colors and schemes and interior upholstery colors and materials These are not outlined in our research Likewise many minor technical adjustments and changes such as a change in tailgate hinge pin diameter are not listed as they don t really affect the overall performance of a given model Changes and modifications covered will only be for those truck models 2500 and 3500 pickup and cab chassis models which were offered with the Cummins Turbo Diesel engine option package Sharp eyed owners may pick up discrepancies and or errors of omission These errors are solely the responsibility of your columnist who was assigned this daunting task went with the information provided by Dodge s data books which are written at the beginning of a model year and do not reflect later running production changes OVERVIEW Warranty began in 1994 with a basic one year 12 000 mile warranty on the entire truck and 5 year 70 000 mile powertrain warranty The separate truck powertrain warranties were consolidated and currently the package is 3 years 36 000 miles on the entire tr
107. nd 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 19 10 97 94 98 BR Steering wander 8 15 97 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 steering 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 19 16 97 94 97 BR Lower steering column noise and or minor lower steering column movement 11 28 97 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 CATEGORY 21 TRANSMISSION TSB MODELS SUBJECT DESCRIPTION 21 12 97 96 97 BR Transfer case shifter buzz or rattle 8 29 97 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 w
108. nditions 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 18 24 99 00 BR 5 9L 24V diesel engine intermittent engine stumble 11 15 99 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 available 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 Eng
109. ng 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 02 13 99 94 99 BR Squeaking noise from rear leaf springs 09 10 99 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 CATEGORY 5 BRAKES TSB MODELS SUBJECT DESCRIPTION 05 04 99 98 99 BR Chassis dynamics diagnosis 05 28 99 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 factory installed options e g snow plow tires or wheels of different size aftermarke
110. 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 21 14 99 00 BR 47RE transmission harsh or early shifts 11 05 99 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 of August CATEGORY 21 TRANSMISSION 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 trailer 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 21 19 99 99 00 BR 47RE delayed TCC lock
111. nsmissions both axle ratios 20 000 GCWR All 3500 automatics 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR Cab Chassis Models Available in regular cab only 2500 is 8 800 GVWR 56 C A cab to axle dimension 3500 is 11 000 GVWR and available in 60 and 84 C A dimensions GCWR is same as tow ratings above Comments The 2000 model year Dodge truck was a production run of only three months Effective on 1 1 2000 Dodge introduced their trucks as 2001 models Coinciding with the 2001 pickups Dodge introduced the 2001 PT Cruiser For corporate average fuel economy CAFE criteria the PT Cruiser is classified as a truck We speculate the long model run of 2001 truck goes hand in hand with the higher mileage PT Cruiser thus giving Dodge an edge in the CAFE numbers The six speed manual transmission remained on back order all year due to high demand 2001 Turbo Diesel Also 2001 5 models What is New New sport and off road badges Added child seat top tether anchors on quad cab rear seat Four wheel disc brakes are standard with vented rotors in rear integral drum parking brake as a 2001 5 model Four wheel ABS standard with new dynamic rear proportioning braking system as a 2001 5 model Servoless speed control for manual transmission diesels Forged aluminum wheel option on 2500 trucks One touch drivers side power window down feature on SLT and packages New engine ratings of 235 HP 460 ft lbs for both five s
112. nted camper A rear stabilizer bar and auxiliary spring comprise the kit 94 96 BR 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 94 96 BR Lower ball joint replacement Two wheel drive This bulletin applies only to two wheel drive vehicles It discusses the service differences in tack 2WD welded ball joints control arms and non tack welded ball joints control arms 94 97 BR Track bar ball joint diagnosis 4x4 only 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 CATEGORY 3 REAR AXLE TSB 03 02 96 5 10 96 03 03 96 8 16 96 MODELS SUBJECT DESCRIPTION 94 96 BR Shudder when pulling away from stop when operated at maximum GVW rating 2500 and 3500 4x2 The bulletin is a supersession of bulletin 16 01 94 If the vehicle exhibits a driveline shudder trucks regular cab while pulling away from a stop at maximum GVW rating the bulletin describes the replacement automatic of the two piece driveline and center support bracket with a single piece assembly transmission and two piece propeller shafts 94 96 BR Droaning noise vibratio
113. ntrols designed to be operated by a gloved hand An optional bench seat with a 40 20 40 center console split is offered with the center console capable of containing a laptop computer and cellular phone Cab is attached to frame using resilient rubber donut cushions Large sloped tinted windshield with parallel wipers driver side air bag open storage nook in right side of dash for future addition of passenger side air bag cruise control buttons on steering wheel and reclining driver seat Chassis All new frames with combinations of boxed and C channeled sections for greater rigidity Front suspension consists of independent coil springs with 4500 pound capacity front axles on 16 tires Rear suspension is 60 long semi elliptic leaf springs on a rigid axle of varying capacity ratings by model for improved ride quality Two axle ratios are offered 3 54 and 4 10 1 Three rear axles are offered Dana 70 for 2500 automatics hybrid Dana 80 for 2500 manual and Dana 80 for 3500 trucks and cab chassis trucks The long tapered rear springs offer a smoother less choppy ride over rough roads The truck bed is rigidly mounted to the frame and is only offered as a sweptside design 8 foot box The bed also features indents in the bed to allow building a framework to carry multi tiered loads Bed tiedown mounts are standard front and rear The tailgate is detachable Engine Ratings The Cummins B 5 9 diesel was offered in two horsepower torque r
114. oking back that was eight long years ago Prior to our first magazine Fall Year 96 24 93 took time to talk to other Turbo Diesel owners who wanted to know FJ ones more about their truck and specifically the Cummins engine At the time f Year 97 oes eeeeeseseetesee este eeeeiees 29 knew the Turbo Diesel Register would work also knew it would be a lot of Year 98 ccecce 34 hard work with an up front monetary investment and the commitment to Vaari ie as ear OO oori aeee eo in enina 38 publish a minimum of four issues that our initial membership had paid for Year OO naines nnns 44 Positive discussions with other club register publishers and an unofficial good Vea O i Aa EEEE T E 49 luck or two from the manufacturers and well was still hesitant Back to the all important concerns time money and writing skills Time In the initial Recall Notices cccccccccccceeceeeeeee 52 two career days it was nothing to stay up until 2 00 a m Money What the heck we took out a second mortgage And writing skills You ve heard the Preventive Maintenance 57 saying if it is to be it is up to me Thus we started the TDR Mechanics Tips eeeeeee 59 PS We hope you ll learn something from the following collection of tips and Dodge technical data Please realize this booklet is just the tip of the iceberg New Owner s Corner ccccccceceee 62 The TDR and its members provide
115. omotive onboard applications and no problems related to use of two digit coding for calendar years are anticipated 08 51 98 99 BR Compass mini trip computer indicates erroneous average miles per gallon distance to empty 11 27 98 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 08 54 98 99 BR Static inside speakers and or side speaker cuts out when power outside mirror operates 12 30 98 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 35 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 qu
116. or dealer diagnosing Wheel vibration on 350 Series trucks with flange type lug nuts 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 BODY TSB 23 04 95 2 10 95 23 29 95 6 9 95 23 43 95 6 14 95 23 52 95 A 23 74 95 12 8 95 23 08 94 1 28 94 23 32 94 4 1 94 20 MODELS 94 95 BR 94 95 BR 94 95 BR 94 95 BR Standard cab only 95 96 BR 94 BR 94 BR 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 shou
117. or white plastic shine a flashlight on the case while looking at the other side of the case The liquid level will clearly show Try this in a garage or other low level light situation David Burton 9 ENGINE If you need to turn the engine over to locate Top Dead Center of a cylinder and lack the special tool to do this job use a 22 mm socket wrench on the alternator pulley nut Turn the engine backwards from its normal rotation backward rotation for servicing is not a concern to keep the pulley from slipping on the belt Or put a socket on one of the crankshaft damper nuts and have an assistant turn the engine over from underneath the truck Member Ed Wash of Alaska wrote in to ask for a solution to oil dripping from the plastic pipe road draft tube under his engine It is normal for a drop or two to come from this tube when the truck has been parked overnight A member solved the same problem by drilling a 1 1 4 hole in the lid of a large Rolaids jar and drilling eight holes around the top of the jar body Drill a horizontal hole at the bottom of the draft tube Slide the lid over the hose and secure the underside with a tie wrap Screw the jar onto the lid It stops the drips Keeps the driveway spotless If you have trouble reading the oil level dipstick without your glasses put the dipstick in a vise and file a V notch in the side of the stick at the full mark and one at the add mark Makes it much easier to r
118. orsen 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 31 CATEGORY 22 WHEELS amp TIRES TSB MODELS SUBJECT DESCRIPTION 22 01 97 94 97 BR Tire and wheel runout 6 13 97 Radial runout 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 TSB MODELS SUBJECT DESCRIPTION 23 03 97 89 93 AD Difficult to clean light colored chalky residue from black plastic body components 2 14 97 94 97 BR 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 d
119. ou re not sure how it will look Take some pictures of the truck have them blown up to 8x10s then use water based colored markers to draw the different schemes on the pictures The indented bottom of a soft drink can makes a good place to mix up a small batch of two part epoxy The handle of a small plastic spoon or fork makes a good stirring stick and an applicator Old gaskets can be tough to remove from parts even with a scraper Chuck a wire wheel into your electric drill and brush them off clean Be sure to wear safety glasses TAPE TRICKS An easy way to keep grease from your hands and other dirt off new brake shoes during installation is to cover the shoe surface with masking tape Remove the tape before you re install the brake drums Masking tape or duct tape wrapped around the ends of the U joints on a driveshaft keeps the bearing caps in place while handling the shaft GET THE RIGHT SIZE THE FIRST TRIP Determining the outer diameter of a piece of tubing or a bolt is easy Just slip the appropriate size open end wrench over the tubing then read the size of the wrench MECHANICAL When installing a gasket that refuses to stay in place during installation put a light coat of chassis grease on the gasket s undersurface then stick the gasket to the metal It will now stay in place during assembly Put a light coat of chassis grease on the gasket s undersurface then stick the gasket to the metal 61
120. pair procedure involving a wave washer is outlined 05 09 96 All Brake noise 10 4 96 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 05 10 96 94 97 BR Chassis dynamics diagnosis 12 13 96 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 CATEGORY 8 ELECTRICAL TSB MODELS SUBJECT DESCRIPTION 08 20 96 96 97 BR Cassette auto load error on RAS code radio 7 19 96 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 08 21 96A 96 BR Wiring harness connector repair packages 10 18 96 This information only bulletin helps the service technic
121. peed and automatic transmissions New optional engine rating of 245HP 505 ft lbs for the six speed transmission Models Available 2500HD as standard cab quad cab short bed long bed cab chassis 4x2 and 4x4 3500 same as above except no short beds Engine Ratings 235 HP 460 ft lbs torque for five speed manual and automatic transmissions 245 HP 505 ft lbs torque HO engine for six speed manual transmission only Transmissions Five speed manual NV4500HD _ 5th overdrive Six speed manual NV5600 6th overdrive available only with the HO engine Four speed automatic 47RE 4th overdrive with locking converter Maximum Tow Ratings 2500 regular cab and quad cab 4x2 and 4x4 both manual transmissions both axle ratios 20 000 GCWR 3500 regular cab and quad cab 4x2 and 4x4 both manual transmissions both axle ratios 20 000 GCWR Exception 3500 4x2 and 4x4 six speed manual with 4 10 axle is rated at 21 500 GCWR 2500 and 3500 regular cab and quad cab 4x2 and 4x4 with automatic transmissions are rated 3 54 axle 16 000 GCWR 4 10 18 000 GCWR Note Maximum permissible trailer weight will vary by model and options Highest trailer weight rating is for a 3500 regular cab 4x2 six speed 4 10 axle 15 150 pounds Lowest trailer weight rating is for a 3500 quad cab 4x4 automatic 3 54 axle 9 000 pounds Cab Chassis Models Available in regular cab only 2500 is 8 800 GVWR 56 C A dimension 3500 is 11 000 GVWR and is
122. ph 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 18 09 99 99 BR Common diagnostic trouble codes caused by an open fuse 05 21 99 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 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
123. place during the mating of the gasketed parts spread a light coat of chassis grease on one surface and place the gasket on it The gasket will then stay in place and be lined up for the rest of the installation Robert Patton When checking the oil level in your automatic transmission it is important to follow the Owner s Manual directions that specify checking the level with the transmission in neutral not in park Does the transfer case shift lever in your 4x4 truck buzz and vibrate Remove the trim and cement a small piece of rubber inner tube to the shift gate in the 2H position Alternatively you can place a wire tie on the lever where it passes through the shift gate W L Mayo and Robert Patton In a standard oil change of the automatic transmission only about five quarts of the old fluid can be drained out To get a complete change for example when switching to synthetic fluid disconnect the transmission cooler line at the radiator cut and fit a piece of hose to the coupler end and place the other end in a five gallon container Put your truck in park with the brake on and start the engine ATF will flow into the container As soon as the flow begins to dwindle immediately shut off the engine Reattach the cooler line and refill the transmission with fresh ATF before restarting the engine It may take up to 11 quarts Scott Dalgleish 23 BODY Charles Shields wrote in to say he had a problem with dust entering his instru
124. r 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 CATEGORY 3 REAR AXLE TSB 03 03 95 5 5 95 03 02 93 5 7 93 MODELS 94 95 BR 92 93 AD 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 11 CATEGORY 5 BRAKES TSB MODELS SUBJECT DESCRIPTION 05 09 95 B 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 jus
125. rk 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 TSB s Issued During 01 CATEGORY 2 FRONT SUSPENSION TSB MODELS SUBJECT DESCRIPTION 02 001 01 94 01 Rear of vehicle sits too high to allow hook up to a fifth wheel trailer 1 19 01 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 vehicle by several inches proving clearance so that most customers can attach their fifth wheel or goose neck trailer to the trailer hitch turntable CATEGORY 5 BRAKES TSB MODELS SUBJECT DESCRIPTION 05 002 01 01 Parking brake pedal adjustment 3 9 01 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 CATEGORY 8 ELECTRICAL TSB MODELS SUBJECT DESCRIPTION 08 010 01 94 02 Airbag clock spring service 5 25 01 When servicing any airbag system it is essential to follow the proper Service Manual and or Diagnostic Manual proced
126. rtant 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 24 27 93 91 93 AD Air conditioner compressor noise 11 19 93 94 BR 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 CATEGORY 26 MISCELLANEOUS TSB MODELS SUBJECT DESCRIPTION 26 04 94 All Diagnostic procedure manuals 10 28 94 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 TSB s Issued During 96 CATEGORY 2 FRONT SUSPENSION TSB 02 01 96A 5 31 96 02 03 96 5 31 96 02 04 96 6 21 96 02 06 96 11 29 96 MODELS SUBJECT DESCRIPTION 94 96 BR Camper Special service kit 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 mou
127. s results in serious fuel leakage Either replace the standard bolt with a modified bolt or check frequently for fuel leakage The fuel filter element should be changed at every other oil change or every 12 000 miles Always prime the fuel filter before placing a new one on the engine Then follow the procedure for bleeding the remaining air from the fuel filter assembly prior to starting On all 12 valve engines with the P 7100 injection pump all 94 98 5 trucks a fuel return line runs from the engine side of the injection pump near the front of the pump to return unused fuel to the fuel tank Part of the line is rubber This rubber line hidden under the intake manifold is subject to heat deterioration and should be replaced approximately every 50 000 miles This problem has been well documented in the TDR Issue 19 page 26 has the best write up See the picture below Look closely for the problematic fuel return line All rubber fuel lines both supply and return should be checked periodically for integrity Some lines can leak fuel or admit air to the system or cause loss of prime and resultant hard starting Starting in 1994 the Cummins engine is equipped with a pre strainer fuel heater It is located low on the left side of the engine in the fuel line before the fuel transfer pump The strainer should be removed for inspection by unscrewing the bottom bowl of the unit The strainer should be cleaned checked at least e
128. sion and California manual transmission California engines continue with EGR Note A 98 5 engine was introduced 1 1 98 to meet more stringent emissions standards It included electronic control of fuel injection and a 24 valve cylinder head Rated at 235HP and 460 ft lbs of torque for manual applications and 215 420 for automatic transmissions No rating difference for California as the 98 5 engine was 50 state certified without EGR Transmissions No changes from 1996 Five speed manual NV4500HD 5th overdrive Four speed automatic 47RE 4th overdrive with locking converter Maximum Tow Ratings 2500 regular cab extended cab quad cab manual 4x2 3 54 or 4 10 axle 20 000 GCWR Except 12 valve California trucks 3 54 axle is 16 000 4 10 axle is 18 000 GCWR 2500 regular cab extended cab quad cab automatic 4x2 and all 4x4 models 3 54 axle 16 000 GVWR 4 10 axle 18 000 GVWR 3500 regular cab manual 4x2 3 54 or 4 10 axle is 20 000 GVWR 3500 extended cab quad cab manual 4x2 and 4x4 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR 3500 extended cab quad cab automatic 4x2 and 4x4 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR Cab Chassis models Available in regular cab only 2500 is 8 800 GVWR 56 C A cab to axle dimension 3500 is 11 000 GVWR and available in 60 and 84 C A dimensions 2500 and 3500 manual have 20 000 pound tow rating with either axle in 4x2 and 4x4 2500 and 3500 automatic 4x2 and 4
129. spected 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 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 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 trans
130. ssis models Available in regular cab only 2500 is 8 800 GVWR 56 C A cab to axle dimension 3500 is 11 000 GVWR and available in 60 and 84 C A dimensions New options include rear helper spring and stabilizer bar group 9 24 section modulus frame snowplow prep group with some engine transmission combos Comments California trucks have exhaust gas recirculation and net horsepower is lower Last full year of the 12 valve engine production 1998 Turbo Diesel What is New Quad cab option featuring doors on each side of extended cab with no B pillar Front seat belts integrated into seats on all extended cab and quad cab trucks New interior with redesigned dash Dash is electronic on 98 5 models 2500 short box extended cab and quad cab model with diesel is available Passenger side airbag with disable switch is standard Next generation airbags Heated power mirrors Illuminated door lock and power window switches Optional security alarm system 24 valve electronic controlled injection diesel offered as a 98 5 model Revised fifth gear nut on five speed manual transmission Models Available 2500HD as standard cab extended cab quad cab short bed long bed cab chassis 4x2 and 4x4 3500 Same as above No short bed models available Engine Ratings 12 valve head mechanical injection pump 215 HP and 440 ft lbs for manual transmission except California 180 HP and 420 ft lbs for automatic transmis
131. support joint 23 64 93 94 BR Tailgate rattles 11 19 93 If tailgate rattles over bumps check for looseness If tailgate does not close tightly replace the overslam and alignment bumpers 23 21 92 93 AD 93 standard paint colors 9 8 92 23 09 91 92 AD 92 standard paint colors 8 26 91 23 12 90 91 AD 91 standard paint colors 10 8 90 23 24 89 90 AD 90 standard paint colors 10 10 89 23 08 89 89 AD 89 standard paint colors 4 10 89 CATEGORY 24 AIR CONDITIONING TSB MODELS SUBJECT DESCRIPTION 24 01 95 A 89 94 AD R 12 to R 134a refigerant adaptation procedure 3 3 95 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 24 06 95 A 94 95 BR Odor from air conditioning ducts 5 26 95 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 24 08 95 94 95 BR White flakes from instrument panel outlet 5 19 95 Sodium silicate is used to coat the air conditioner evaporator for corrosion protection If excessive amounts are applied 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
132. t and deep throttle 2 4 up shift A complaint 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
133. t retractor cover 05 21 99 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 23 22 99 94 00 BR Rattle in door area 07 02 99 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 23 28 99 98 99 BR Power seat track vertical adjustment stuck in a full upward or full downward position 08 13 99 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 23 35 99 94 00 BR Child seat tether anchors Rev A This bulletin supersedes technical service bulletin 23 35 99 dated Sept
134. t short of Club Chassis only antilock 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 installing 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
135. t truck and how do you make sure it has been well maintained You surely don t want to buy a lemon when an engine can cost upwards of 7 000 a new transmission can cost upwards of 3 500 and a P 7100 rebuilt injection pump can cost you 1 400 Here are some buying tips to help you find just the right one for you Keep in mind that this is likely the second largest purchase you ll ever make second only to a home Some folks spend more on their transportation in their lifetime than they spend on housing While you may live in one place your entire life the average owner trades vehicles once every five years Every dollar saved on the purchase price of either a home or a vehicle will also save on interest dollars paid back if you are getting a loan So a dollar saved may actually amount to as much as 1 25 over the life of the loan Inform Yourself Before you ever set foot on a dealer lot or peruse the want ads take the time to familiarize yourself with the various models and options offered by the manufacturer and see how they match your intended use Narrow your search down to those models and model years which fit your budget and which will do the intended job Select only those models with the options you want Make a list of specifications keep it with you during your search and keep to your list For example if you determine you want a truck for hauling and towing but want an extended cab model with SLT interior do the
136. t 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 05 11 99 94 96 BR Revised power brake booster check valve 12 31 99 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 CATEGORY 8 ELECTRICAL TSB MODELS SUBJECT DESCRIPTION 08 06 99 98 00 BR Radio interference to from two way radio receivers Rev A This bulletin supersedes technical service
137. 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 CONCLUSION Wow what a listing of information Thanks again to the TDR members that forward information to us Also thanks to those at DaimlerChrysler and Cummins that provided their insight 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 54 TURBO TIPS The following is a collection of tips minimal cost modifications and solutions found by Dodge Cummins Turbo Diesel owners in real life operation of their vehicles It is gleaned from previous issues of the Turbo Diesel Register and is sometimes edited for brevity and clarity The categories in this harvest of hints follow the system of classification used in Dodge s Technical Service Bulletins 3 REAR AXLE own be sure to mix thoro
138. 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 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 wh
139. 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 obump in the floor pan of the vehicle The sound will only occur when the fuel level of the vehicle is between 1 2 and 7 8 tank of fuel Since the fuel level of the vehicle must be between 1 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 procedure 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
140. tin 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 A revision in the injection pump timing specification on Cummins engines with a CPL 2022 or 2023 should be utilized when checking or performing injection pump timing CATEGORY 19 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 appropri
141. tin 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 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 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
142. tion 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 number as follows Warren S in the 11 VIN position through April 4 1996 St Louis J 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 in
143. tle in your name Either a bill of sale from a dealer or a signed title from the owner should be placed in your hands at the time you give them your check no exceptions and no excuses by the seller Remember the job s not done until the paperwork is right Make sure the serial number on all paperwork agrees with the serial number stamped into the left front corner of the dashboard Paperwork mistakes in this area are frequent and hard to correct later Before driving your new purchase home call your insurance agent to insurance Failure to do so could have disastrous consequences just down the road Finally if there is any remaining warranty on the vehicle be sure to fill out and send in the paperwork to get it transferred to you If the truck is less than five years old and has less than 100 000 miles on the odometer you should transfer the remaining engine warranty That s it You now own your new to you truck and if you have researched fully and purchased carefully you ll have many miles of enjoyable cruisin ahead of you 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
144. to pour new oil into your engine if you make your wobble proof funnel from a used plastic 1 75 liter Skol Vodka jug It seems the spout diameter and lid threads are an exact fit to the oil fill opening and threads on your Cummins engine R J Stamper Member Scott Morneau adds that you can use the oil fill cap to test other potential bottles If the oil fill plug fits the cap of the bottle the bottle will likely fit in the oil fill port We are reminded that when changing engine oil the new filter should be primed with clean oil the filter will hold nearly a quart before installation on the engine This will cut the time the engine runs without oil pressure during its first start after the oil change Gus Hrncir Here s a free pre luber for your Cummins engine If your engine is not run for long periods or if you want to build oil pressure before starting it in cold weather or after an oil change disconnect the fuel shutoff solenoid wire and crank the engine for 15 seconds Reconnect the wires and crank it again to start it Its an almost free solution if you add a switch in the cab to make raising the hood unnecessary Excerpted from the Cummins Operations Manual the tip applies to all the 12 valve engines Here s the editor s all time favorite low cost service tip When removing the oil filter use a large heavy duty freezer bag After loosening the filter part way slide the zip loc freezer bag under and around the filter
145. uck including powertrain Engine warranty has stayed constant at 5 years 100 000 miles Tow Ratings have changed considerably from year to year and from option model to option model and even within option models so read carefully if you are interested in or seeking such information Some models were are rated to tow much less weight than others Watch out for lightweights PROBLEM AREAS Please keep in mind that there is no such thing as the perfect truck or car All vehicles will contain certain designs systems or parts that are more prone to failure than might normally be expected Looking at these negatives the image of the vehicle can be tarnished However to look on the positive side the owner is aware of the problems and can take corrective action and make informed decisions With these thoughts in mind the following are common problem areas on the subject trucks Common Problem areas 1994 1998 5 Included failed engine start run solenoids frayed throttle cables hard start due to degradation of the rubber fuel return line automatic transmissions problems that were often caused by fluid loss at transmission line to cooler line to transmission quick couple plastic fittings poor fuel filter access loss of fifth gear in five speed transmissions failed front end parts on 4x4 models poor front brake pad life in certain applications poor paint adhesion of certain colors failure of throttle position sensors on automati
146. ughly before pouring it into the TDR member John Holmes gives some tips for ensuring that rear differential lube is at the proper level following a differential oil change Jack up each side of the rear axle for five minutes each to ensure that oil reaches the axle bearings then lower the truck to a level floor and check the fluid level Add additional fluid as necessary to complete the fill On some trucks with heavy duty suspension and overload springs suspension noise from the overload springs slapping the frame stop can be annoying Slip and tighten a plumber s pipe connector over the end of the frame stop A plumber s pipe connector is a 3 diameter rubber tube about 4 long and about 3 8 thick with a stainless steel hose clamp on each end It is available at plumbing supply shops or stores such as Home Depot for about 4 00 each Frank Howatt Another method to cure overload spring slap is to cut and fit a piece of old tire carcass to the overload spring end using one clamp to attach it at the axle end only The cost is less than a dollar per side John Holmes 7 COOLING 1989 and 90 Turbo Diesels were not equipped with an air to air intercooler These trucks tend to run hot in the summer on long pulls Member Tom Clayton used a section of 4 aluminum dryer vent hose to direct cool air from the front of the truck onto the turbocharger area He also installed a revised Cummins thermostat P N 3802273 which further impro
147. uipped 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 reception 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 CATEGORY 8 ELECTRICAL Continued 08 45 93 10 8 93 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 94 BR 91 93 AD 94 BR All trucks 89 91 AD 91 AD Radio lock up The bulletin applies to AM FM Stereo RAL or AM FM stereo cassette RAS radios If the buttons and controls do not function the condition is caused by a programming error The condition is corrected by following the operational sequence outlined in the
148. ulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module PCN with new software 21 08 00 99 00 BR 47RE delayed TCC lock up and or MIL P1740 TCC or O D Solenoid Performance 09 01 00 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 situations 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 21 12 00 00 01 BR Tapping knocking sound during idle 09 15 00 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
149. ures 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 CATEGORY 9 ENGINE TSB MODELS SUBJECT DESCRIPTION 09 002 01 98 01 BR Exhaust manifold bolt retention straps 03 02 01 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 contr
150. usty 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 odor results The repair involves cleaning the evaporator with Mopar aerosol cleaner 33 TSB s Issued During 98 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 dies
151. ut with a voltmeter may show it is putting out 14 8 volts or more when it should charge at 14 2 volts When the rubber boot covering your positive battery terminal connector becomes worn replace it with an old spark plug wire boot or make a sleeve type cover from an appropriate size plastic bottle Just a reminder when replacing quartz halogen lights use clean cloth gloves or otherwise cover the bulb with clean cloth or paper to prevent oil from your hands getting on the glass Finger oils make the glass shatter under high heat conditions LUBE TIPS Trying to pour oil or other fluid into a fill hole and don t have a funnel handy Stick a screwdriver in the fill hole and pour the liquid down the screwdriver shaft It will follow the shaft into the fill hole Need some good parts cleaning solution but hate to spend the bucks Use old automatic transmission fluid It will make greasy parts shiny clean after an overnight soaking Wash the ATF off with soapy water If you have a mysterious oil leak on your automatic transmission check where the transmission dipstick tube goes into the case You ll likely find a cracked O ring when you remove the dipstick tube Replace the O ring for a quick fix FILTER TIPS If your engine oil filter or fuel filter simply refuses to budge when you re trying to remove it let the engine fully cool off and it may be much easier to remove To make the job of removing your oil filter
152. ved engine cooling To protect the cooling system from bugs and debris insert an old aluminum framed window screen behind the grille and ahead of the radiator or simply cover the radiator with window screen material Then a few taps of the hand will remove the collected bugs This quick fix provides a free or almost free preventive maintenance solution For extreme cold weather operation if you install a winter front radiator cover on your truck it must have a minimum one square foot opening in its center for radiator and intercooler airflow This tip is from the Cummins 5 9 Liter Engine Operation s Manual The correct type of antifreeze coolant to use in your Turbo Diesel is an ethylene glycol not propylene based product If possible use a low silicate diesel type of coolant It should be mixed fifty fifty with distilled water Or you can buy a pre mixed product But if you mix your cooling system 8 ELECTRICAL On 89 93 trucks the voltage regulator seemed to fail too often Member Earl Peck solved the problem by relocating the regulator to the front of the hood pivot assembly on the left side of the engine away from all the engine s heat His regulator hasn t failed since On second generation trucks Dodge redesigned the system and the regulator is integral with the alternator and it is not a problem On some maintenance free batteries it is possible to check the electrolyte level If the case is transparent
153. very 40 000 miles or more often if contaminants clog your primary fuel filter This strainer is not shown in any Cummins parts books It has been the culprit for many complaints of low power as it performs its designed task of screening the fuel prior to the primary fuel filter 57 58 16 PROPELLER SHAFT AND U JOINTS Trucks with two piece driveshaft systems extended cab trucks can experience a vibration when towing a heavy load at engine peak torque RPM in lower gears The vibration lessens and then disappears as engine speed builds This vibration is caused by the center carrier bearing being moved sideways against the bearing carrier frame and is considered normal 18 VEHICLE PERFORMANCE All 4x4 trucks built after 1994 use engine vacuum to engage the front axle drive Periodically inspect the vacuum hoses going to the front axle for holes abrasions and splits A damaged vacuum hose will prevent the front axle from engaging when the 4x4 lever is shifted in the cab 19 STEERING A steering clunk in two wheel drive trucks produced after 1993 can be traced to lube pushing out of the telescoping steering column parts into the rubber boot on the shaft Squeezing the boot to push lube back into the splined area is a temporary cure for the clunk A replacement steering shaft coupler is a long term solution In 4x4 models a clunk similar to that found in two wheel drive trucks may be caused by faulty track bar
154. wer mirror support bracket onto the driver s side mirror 23 61 97 94 98 BR Noise coming from cargo box area 11 28 97 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 on two cargo box cross member rails 23 67 97 98 BR Upper rear corner of front door contacts upper front corner of cargo door 12 6 97 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 23 68 97 98 BR Water leaking into vehicle through side cowl panel 12 19 97 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 CATEGORY 24 AIR CONDITIONING TSB MODELS SUBJECT DESCRIPTION 24 11 97 94 98 BR A C evaporator odor 7 11 97 This bulletin supersedes technical service bulletin 24 06 95A dated 5 26 95 Some vehicle operators may experience a m
155. x4 have 16 000 GCWR with 3 54 axle and 18 000 GCWR with 4 10 axle Comments Watch tow ratings carefully Mid year introduction of the 24 valve engine for cleaner emissions Early problems with failed fuel lift pumps and locked up injection pumps Owners find out that a 4 10 1 axle ratio is better for towing with the 24 valve engine since the power band has been moved higher in the RPM range 24 valve engine governed RPM is raised to 3 200 Electronically controlled fuel injection produces a flat torque curve from 1700 2700 RPM In November of 98 Dodge issues a bulletin to all dealers informing them that exhaust brakes are not approved for use with automatic transmission equipped trucks Issue 24 page 38 1999 Turbo Diesel What is New Deleted extended cab option in middle of model year Deleted side body trim from aft of rear wheels Electronic dash with all gauges run by computers Models Available 2500HD as standard cab extended cab quad cab short bed long bed cab chassis 4x2 and 4x4 3500 same as above except no short beds Engine Ratings Same as 98 5 model year 24 valve electronic injection control 235HP 460 ft lbs torque for manual transmissions 24 valve electronic injection control 215HP 420 ft lbs torque for automatic transmission Peak torque available from 1700 2700 RPM Transmissions Five speed manual NV4500HD 5th overdrive Four speed automatic 47RE 4th overdrive with locking converter
156. ylinder head coolant passage on engines built before engine serial number 44465181 may result in a stuck t stat in the open or closed position A revised t stat and coolant passage diameter check a part of the repair procedure 07 04 91 90 91 AD Lower radiator hose leakage 9 23 91 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 07 05 91 91 AD Fan belt noise chirp 12 16 91 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 07 03 90 All Recycled engine coolant 12 21 90 The use of reconstituted antifreeze coolants is not authorized in the performance of any repair covered under the provisions of warranty 07 01 89 88 89 with Auxiliary oil cooler freeze up 2 27 89 automatic At ambient temperatures of 10 F or lower trucks with auxiliary coolers NHB may loose transmission transmission fluid due to a restriction of oil flow A bypass line is the recommended repair CATEGORY 8 ELECTRICAL TSB MODELS SUBJECT DESCRIPTION 08 25 95 94 95 BR Power mirror vibration associated with installation of bugscreen deflectors 6 9 95 The symptom is blurred images in the power mirrors The diagnostic procedure remove the bugscreen If vibration ceases the mirrors are ok
157. ystem changes mode to defrost when accelerating 10 18 96 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 24 12 96 96 BR Water leaks from HVAC floor outlet onto floor 8 2 96 Vehicles assembled Water may drain out of the HVAC floor outlets while operating the A C system The bulletin between 2 1 96 and 6 describes the diagnosis and repair procedure 28 96 with a VIN code 3 as the first digit 24 16 96 95 96 BR Vacuum system contaminated with engine oil 10 11 96 With engine serial Some Turbo Diesel trucks were produced without a check valve on the vacuum pump Without number 56230585 thru a check valve oil may enter the vacuum system A visual inspection of the HVAC system is 56293178 or presented and the repair procedure outlined 45232867 thru 45360437 These engines were installed befor 6 1 96 YOU MIGHT BE A FORD CHEVY OWNER IF 1 You write off a radiator as a business expense 2 Your truck is insured by Smith amp Wesson 3 There is a puddle in your driveway year round 4 Your stereo speakers used to belong to the Moonlight Drive in Theater 5 Your wife has ever said Come move this transmission so can take a bath 6 You read the Auto Trader with a highlight pen

CATEGORY 8 ELECTRICAL...Continued

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