TSB Ram 3500

TECHNICAL
SERVICE
BULLETINS
1989-2012
A Publication of the Turbo Diesel Register
Over the Years

Dodge Technical Service Bulletins
Not surprisingly, there have been comments by those unfamiliar
with the truck (prospective new/used buyers, Internet, truck
shows) that the Turbo Diesel certainly has its share of
problems. To them, no doubt, the grass looks greener on the
other side.
Although some will dwell on the problems, the majority of
owners take initiative to solve/correct, anticipate/prepare for a
future situation. Thats 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
3 Rear Axle
5 Brakes
6 Clutch
7 Cooling
8 Electrical
9 Engine
11 Exhaust
13 Frame & Bumpers
14 Fuel
16 Propeller Shafts & U-Joints
18 Vehicle Performance
19 Steering
21 Transmissions
22 Wheels & Tires
23 Body
24 Air Conditioning
26 Miscellaneous
TABLE OF CONTENTS
Technical Service Bulletins
1989-1995 TSB................................ 3
1996 TSB....................................... 16
1997 TSB........................................ 21
1998 TSB........................................ 26
1999 TSB........................................ 30
2000 TSB........................................ 36
2001 TSB.........................................41
2002 TSB........................................ 44
2003-2009 TSB............................... 50
2010 TSB........................................ 76
2011 TSB......................................... 80
2012 TSB........................................ 85
Recalls
1997-2009 Recalls.......................... 93
2012 Recalls.................................... 99
A note concerning the TSBs and their use: the bulletins are
intended to provide dealers with the latest repair information.
Often the TSB is vehicle identification number (VIN) specific.
VIN data on the Chrysler service network helps the dealer in his
service efforts. A TSB is not an implied warranty.
2
A Publication of the TURBO DIESEL REGISTER
TSBs Issued During 1989-1995

CATEGORY 2
FRONT SUSPENSION
TSB #
MODELS
SUBJECT/DESCRIPTION
02-05-95
5/15/95
94 - 95 (BR)
4x4 4x2 Cab Chassis
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.
02-02-94
2/11/94
94 (BR)
Service manual revisions for torque values on front suspension.
02-07-94
6/15/94
94 (BR)
This information bulletin differentiates the track bar used on different vintage trucks.
02-08-94
7/22/94
94 2500 (BR)
Cab Chassis
with sales code XBC
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.
02-20-94
12/2/94
94 (BR)
Service manual revision for torque values on stabilizer link bar.
02-02-91
1/28/91
92 (AD) 2WD
vehicles only
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.
02-06-90A 90 - 91 (AD) 2WD

12/17/90
vehicles only
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.
02-09-90
11/19/90
Service manual revision for camber specification.
89 - 90 (AD) 4WD
CATEGORY 3
REAR AXLE
TSB #
MODELS
SUBJECT/DESCRIPTION
03-03-95
5/5/95
94 - 95 (BR)
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.
03-02-93
5/7/93
92 - 93 (AD)
Launch shudder/vibration.
For 1992-1993 131 or 149 wheelbase trucks. Describes repair procedure to adjust the pinion
angle of the rear-end to eliminate vibration or shudder in the 1-2 shift made at medium to heavy
throttle. This TSB does not address wheel hop that occurs with manual transmission trucks at
start off. Wheel hop is a function of driveline spring wrap up because of high torque being exerted
on the pinion shaft.
CATEGORY 5
BRAKES
TSB #
MODELS
SUBJECT/DESCRIPTION
05-09-95 B
9/22/95
94 - 95 (BR)
All 4x4 and 3500 4x2
Club Chassis only
Drift left or right under moderate or hard braking.

The symptom is a drift right or left during moderate to hard brake applications just short of 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
3/24/95
94 - 95 (BR)
3500 4x4/4x2
2500 4x4
Front brake noise on trucks with 86 mm diameter caliper pistons.

The symptom is a squeal noise when applying the brakes for a normal stop. The repair involves
grinding or filing a chamfer on both ends of the front brake pads.
05-03-94
3/4/94
94 (BR)
Service manual revision for brake bleeding procedure on trucks equipped with ABS brakes.
05-21-94
10/21/94
89 - 93 (AD)
Premature brake wear on trucks with 12 brake drums.

The bulletin involves replacement of the rear brake shoes (linings) with revised shoes.
05-08-93 A
9/3/93
94 (BR)
Pedal feel/characteristics of ABS brakes is the subject of this information only bulletin.
05-15-93
11/1/93
94 (BR)
Brake pedal noise.

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
4/21/92
89 - 92 (AD)
sales code BKH, BKJ
Premature brake wear on trucks with 12 brake drums.

The bulletin involves replacement of the rear brake shoes (lining) with revised shoes.
05-01-91
1/28/91
81 - 91 (AD)
Rear wheel anti-lock speed sensor connector repair procedure.

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
8/12/91
90 - 91 (AD)
Front disc brake noise from Bendix disc brakes.

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
9/24/90
89 - 90 (AD)
Rear wheel anti-lock faults caused by water contamination.

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
8/12/94
89 - 93 (AD) with
manual transmission
Transmission noise below 1400 rpm.

The bulletin describes a powertrain induced cyclic noise condition that appears to be transmission/
driveline related. Especially noticeable in 4th and 5th gears, the noise occurs below 1400 rpm during
coast or light throttle. The noise is not damaging to the powertrain and is due to the dampening
characteristics of the clutch springs. The revision, if needed, involves replacement of the clutch disc.
Transmission noise below 1400 rpm.
CATEGORY 6
06-01-90 A
12/31/90
CLUTCHcontinued
The bulletin describes a powertrain induced cyclic noise condition that appears to be transmission/
driveline related. Especially noticeable in 4th and 5th gears, the noise occurs below 1400 rpm
during coast or light throttle. The noise is not damaging or durability related. The diagnosis
involves a road test to pinpoint the rpm at which the noise occurs. The revision involves a change
of the flywheel.
89 - 91 (AD) with
manual transmission
CATEGORY 7
COOLING
TSB #
MODELS
SUBJECT/DESCRIPTION
07-04-94
4/8/94
94 (BR)
Service manual revision - thermostat seals.

Revised service manual pages showing t-stat seal pictures.
07-07-94
9/30/94
94 - 95 (BR)
Engine slow to warm-up in cold ambient temperatures.

The bulletin describes an overcooling condition caused by the thermostat being stuck in a partial
open position. Gauge fluction is addressed and is considered normal with no action required.
Owners are advised that the cooling system is large to provide capacity and protection for high
temperatures and high GCWR ratings. Slower warm-ups are to be expected.
07-01-91
1/28/91
89 - 90 (AD)
Overheating or no heat condition.

An interference between the thermostat and cylinder head coolant passage on engines built
before engine serial number 44465181 may result in a stuck t-stat in the open or closed position.
A revised t-stat and coolant passage diameter check a part of the repair procedure.
07-04-91
9/23/91
90 - 91 (AD)
Lower radiator hose leakage.

Some leakage from the lower radiator hose at the waterpump connection may occur due to a step
cast in the water pump nipple. The repair involves installing a second hose clamp.
07-05-91
12/16/91
91 (AD)
Fan belt noise/chirp.

The noise is caused by excessive paint in the grooves of the water pump allowing the belt to slip.
Wire brush and solvent to remove the paint is the repair procedure.
07-03-90
12/21/90
All
Recycled engine coolant.

The use of reconstituted antifreeze/coolants is not authorized in the performance of any repair
covered under the provisions of warranty.
07-01-89
2/27/89
Auxiliary oil cooler freeze-up.

88 - 89 with
automatic transmission At ambient temperatures of -10F or lower, trucks with auxiliary coolers (NHB) may loose
transmission fluid due to a restriction of oil flow. A bypass line is the recommended repair.
CATEGORY 8
ELECTRICAL
TSB #
MODELS
SUBJECT/DESCRIPTION
08-25-95
6/9/95
94 - 95 (BR)
Power mirror vibration associated with installation of bugscreen deflectors.

The symptom is blurred images in the power mirrors. The diagnostic procedure - remove the
bugscreen. If vibration ceases the mirrors are ok. Bugscreen deflectors are designed to disrupt
airflow which can lead to mirror/antenna vibration.
08-24-95
9/30/95
94 - 95 (BR)
Accessory frame ground jumper wire.

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.
CATEGORY 8
08-22-95
5/12/95
94 - 96 (BR)
89 - 93 (AD)
Installation of radio equipment.

The bulletin supersedes 08-31-94, 7/15/94 and discusses the proper installation of communication
equipment in Chrysler vehicles.
08-16-95 A
94 - 96 (BR)
89 - 93 (AD)
Speed control - over/undershoot during set of speed selection.

The bulletin discusses the adaptive strategy that compensates for vehicle-to-vehicle variations in
speed control cable lengths. Pressing the set button without pressure on the accelerator pedal
can cause speed fluctuations. Proper review of the condition with vehicle operator is recommended.
08-05-94
1/20/94
94 (BR)
Poor AM radio reception.

Tighten the antenna base to 70 in/lbs to assure reception.
08-06-94
2/4/94
ELECTRICALcontinued
94 (BR)
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.
08-08-94 A 94 (BR)
5/20/94
Weak sounding horn.

The bulletin discusses an upgrade from a single horn to a dual horn system.
08-10-94
2/18/94
94 (BR)
Fuel gauge sticks.

The bulletin covers replacing the fuel pump module, if the fuel gauge intermittently sticks at full,
with less than full capacity.
08-17-94
4/1/94
94 (BR)
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.
08-29-94
6/24/94
94 (BR)
Diesel secondary battery does not chargevehicles 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.
08-33-94
7/15/94
91 - 93 (AD)
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.
08-41-94
8/5/94
94 - 95 (BR)
Trailer tow brake wire location.

An information only bulletin showing the wiring provisions for an electric brake actuator.
08-64-94
11/4/94
94 - 95 (BR)
Power mirror vibration.

On vehicles equipped with power mirrors built prior to 9/18/94 this TSB discusses the diagnosis
and repair for excessive vibration/blurred images.
08-65-94
11/4/94
94 (BR)
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.
08-05-93
2/8/93
93 (AD)
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.
08-07-93 A
3/19/93
92 - 93 (AD) with
four wheel drive
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.
08-45-93
10/8/93
94 (BR)
Radio lock-up.
CATEGORY 8
ELECTRICALcontinued
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 TSB.
08-47-93
10/15/93
94 (BR)
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.
08-58-93
12/10/93
91 - 93 (AD)
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.
08-67-93
12/31/93
94 (BR)
Service procedure for the stop light switch connector.

An information only bulletin showing the disconnect procedure of the stop light switch.
08-05-91
4/22/91
All trucks
Trailer tow wiring installation.

The information only bulletin gives guidelines for proper wiring of trailer tow wiring packages.
08-10-91
9/9/91
89 - 91 (AD)
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.
08-11-91
10/7/91
91 (AD)
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
ENGINE
TSB #
MODELS
SUBJECT/DESCRIPTION
09-10-95
6/2/95
94 - 95 (BR)
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.
09-04-95
4/14/95
94 - 95 (BR)
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.
09-06-94
4/22/94
94 (BR)
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.
09-22-93
12/31/93
94 (BR)
Service manual revision for Cummins piston grading procedure. The information only bulletin
details the pistons to be used if engine rebuild is necessary.
09-07-91
12/2/91
91 - 92 (AD)
Cylinder head bolt torque tightening procedure.

The information only bulletin describes the bolt tightening procedure for cylinder head bolts.
09-11-89
7/3/89
Knocking noise at rear of engine due to a cracked torque converter drive plate.
89 (AD) with
automatic transmission 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
5/13/94
94 (BR)
Diesel exhaust stains.

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
7/27/92
88 - 92 (AD)
Rear tailpipe support bracket cracking.

The condition is a rattle noise caused by a crack or break in the rear tailpipe support bracket area.
A revised tailpipe support bracket (5 2018458) is the part used for repair.
CATEGORY 14
FUEL
TSB #
MODELS
SUBJECT/DESCRIPTION
14-05-94
4/8/94
94 (BR)
89 - 93 (AD)
Use of low sulfur fuel.

The bulletin discusses the new for 1994 low sulfur fuel. Fuel lubricity concerns are addressed as
the use of diesel fuel additives to increase the lubricity of low sulfur fuel are not required.
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
12/3/90
89 - 90 (AD)
Accelerator pedal effort too high.

The bulletin describes the installation of revised parts to lessen the pedal effort. If the truck has
a Mopar aftermarket speed control kit, the kit already has the revised parts.
14-01-89
10/2/89
89 (AD)
Injection pump diagnosis procedure.

A troubleshooting procedure is outlined to help diagnose diesel engine problems.
CATEGORY 16
PROPELLOR SHAFTS & U-JOINTS
TSB #
MODELS
16-02-95
11/3/95
94 - 95 (BR)
Droaning noise/vibration.
automatic transmission The symptom/condition is a droaning type noise and/or vibration felt in seat track, floor pan or
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 rpm on 4x4 models with torque converter
clutch engaged. The repair involves replacement of the propeller shaft.
16-01-94
10/14/94
94 - 95 (BR)
SUBJECT/DESCRIPTION
Shudder at start on vehicles with two piece driveshafts operated at near maximum GVW.
The symptom is a driveline shudder when pulling away from a stop. As the vehicle is loaded, the
driveline angle will change. In the case of maximum GVW, the rear differential may rise above
the rear driveshaft center bearing. The alignment could cause a shudder in the driveline. The
repair involves replacement of the driveshaft center support bearing bracket and/or driveshaft.
CATEGORY 18
VEHICLE PERFORMANCE
TSB #
MODELS
18-29-95 A
10/16/95
94 - 95 (BR) with
Diesel low power/performance specs.
automatic transmission 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.
18-01-94
1/14/94
94 (BR) with
Lack of power/harsh transmission shifts.
automatic transmission 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.
18-10-94 A
7/29/94
94 (BR)
18-05-93
4/30/93
91 - 93 (AD)
18-06-92 A
7/23/93
SUBJECT/DESCRIPTION
Excessive White Smoke/Low Power.

The bulletin involves a diagnostic check of the cooling system and starting instructions before
verifying timing of the engine. Manual transmission engines are set to 12.5 degrees top dead
center. Automatic engines should be set according to the engine data plate.
Poor 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
91 - 93 (AD) with
automatic transmission 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.
18-05-92
6/15/92
92 (AD)
18-06-92
6/29/92
91 - 92 (AD)
18-10-92 A
9/8/92
91 - 92 (AD) with
automatic
transmission
18-11-92
7/13/92
91 - 92 (AD)
18-17-92
9/8/92
91 (AD)
18-18-92
10/19/92
91 - 92 (AD)
18-15-92
91 (AD)
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 33F some vehicles may be slow to accelerate or feel low on power. The condition may
be caused by ice forming at the fuel intake area of the fuel gauge sending unit module. A revised
module part number and repair procedure are outlined.
Erratic 3-4 or 4-3 shifter.
Note: See TSB 18-06-93 A
Poor performance/lack of power.
Note: See TSB 18-05-93
Engine rpm fluctuates when the cruise control is engaged.
This bulletin is for non-intercooled (build date prior to 1/1/91) trucks. The bulletin involves replacing
the vehicle speed control module with a recalibrated module.
Poor engine performance/erratic engine operation/transmission operation.
Some vehicles may exhibit the above characteristics as well as transmission hunting. Corrosion
or spreading of the female terminals in the 3-way throttle position sensor connector could be the
problem. Diagnosis and repair as necessary.
White smoke at start-up.
At cold ambient conditions white smoke can be a condition. This bulletin applies to trucks built
after 1/1/91. The repair involves replacing the air temperature sensor. If the engine serial number
is higher than 44623028 the sensor is of the new design.
CATEGORY 19
STEERING
TSB #
MODELS
SUBJECT/DESCRIPTION
19-02-05 B
11/3/95
94 - 95 (BR) trucks
with a build date prior
to 1/1/95
Clunk or rattle felt in steering wheel/column over rough surfaces or while making a turn.
The repair involves performing an inspection of suspension and steering components to assure
proper torque. The replacement of the steering column intermediate shaft is described.
19-01-94
1/28/94
94 (BR) 4x4
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.
19-04-94
6/3/94
94 (BR)
Low power assist in cold ambient temperatures.

The condition can be minimized by reviewing the cold start procedures. Cold climate power steering
fluid (pn 04778524) may be used.
19-03-93
4/16/93
89 - 93 (AD)
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.
19-02-91
4/22/91
89 - 91 (AD) with four Steering wheel off-center.

Due to a shift in the steering gear bracket in high load conditions, the steering wheel may be off
wheel drive
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.
CATEGORY 21
TRANSMISSION
TSB #
MODELS
SUBJECT/DESCRIPTION
21-02-95
3/31/95
95 (BR)
built after 3/20/95
Quick connect removal and reconnect procedure.

The bulletin is an information only bulletin outlining two ways to disconnect the quick connectors
of the automatic transmission lines.
21-03-95 A
6/16/95
94 - 95 (BR)
Automatic transmission cold temperature cooler bypass kit.

The condition occurs at ambient temperatures of -15F 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.
21-04-95
4/14/95
94 - 95 (BR) trucks
with automatic
transmission
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.
21-05-95 A
1/5/96
94 - 95 (BR) trucks
with automatic
transmission
21-08-95
1/30/95
94 - 95 (BR)
21-09-95
6/30/95
94 - 95 (BR) trucks
with manual
transmission
Delayed transmission engagement/torque convertor drainback.

The condition is delayed transmission engagement of 2 to 8 seconds at initial start-up. The problem
is most noticeable after the vehicle has been parked for an extended period. The bulletin describes
the installation of transmission lines with a one-way drainback valve.
Speed sensor oil seepage.
The bulletin describes how oil seepage can occur in the speed sensor area. The repair is the
installation of a speedometer adapter.
Servicing of 5th gear mainshaft nut on NV 4500 manual transmission.
The information only bulletin describes the replacement of the 5th gear main-shaft nut with a new
nut if the original nut has to be removed. Under no circumstances is the original part to be reused.
Special Mopar lock seal should be applied to the threads at reassembly.
Overdrive unavailable in extreme cold temperatures.
10
CATEGORY 21
TRANSMISSIONcontinued
21-11-95
7/7/95
96 (BR) trucks with

automatic
transmission
The information only bulletin emphasizes a change to the PCM for 1996. For 96 in ammbient
temperatures of -5F and below 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.
21-04-94
3/4/94
94 (BR) with
manual transmission
NV 4500 HD
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.
21-10-94
5/27/94
94 (BR) with
manual transmission
NV 4500 HD
Shift lever contacts instrument panel.

Inspect the shift lever to transmission stub shaft connection. Reseat the lever to the stub shaft if
necessary.
21-17-94
9/16/94
94 (BR) 93 (AD) with

automatic
transmission
Transmission diagnostic reference supplement.

To assist in the repair of automatic transmission, the information only bulletin, lists symptom/cause/
correction information.
21-18-94
9/30/94
94 (BR), 89 - 93 (AD) Transmission 4-3 downshift clunk.

with automatic trans.
A driveline clunk or harshness occurs during 4-3 coast downshift repair as described in bulletin.
21-24-94
12/2/94
94 - 95 (BR) with
automatic trans.
Shift linkage adjustment.

The information only bulletin explains how to correct a PRNUL misalignment.
21-25-94
12/23/94
94 - 94 (BR) with
NP 241 HD transfer
case
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.
21-23-93
9/3/93
92 - 93 (AD) with
Lack of 3/4 up-shift and deep throttle 2/4 up-shift.
automatic transmission 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.
21-39-93
12/31/93
89 - 93 (AD) with
automatic
transmission
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.
21-18-92
11/30/92
92 - 93 (AD) with
automatic
transmission
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.
21-11-91
89 - 91 (AD) with
A 518 automatic
transmission
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.
21-05-90
2/26/90
89 - 90 (AD) with
manual transmission
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.
21-14-90
5/7/90
90 (AD) with 518

Low/reverse band wear.
automatic transmission Premature wear of the low/reverse band may be the result of one of the overdrive transmission
mounting bolts making light contact with the band strut resulting in incomplete release of the band.
A washer is installed to prevent contact.
21-12-89
5/1/89
89 (AD) with
manual transmission
Speedometer drive gear replacement procedure.

An information only brochure to supplement the service manual.
11
CATEGORY 22
WHEELS & TIRES
TSB #
MODELS
SUBJECT/DESCRIPTION
22-03-95
3/3/95
95 (BR)
Match mounted tire/wheel combinations.

The bulletin is an information only bulletin describing a match mounting process to improve ride
characteristics.
22-04-95
4/7/95
94 - 95 (BR)
Spare tire winch operation.

The bulletin is an information only bulletin reminding not to use power tools to drive the spare
tire winch.
22-05-95 A
6/30/95
94 - 95 (BR) with
code WDC wheels
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.
22-06-95
6/16/95
95 (BR)
Match mounting during wheel service.

The information only bulletin helps dealers match mount wheels and tires.
Premature rust on chrome wheels.
22-03-94
6/24/94
94 (BR)
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.
22-05-93
7/16/93
93 (AD)
Tire and wheel runout.

A quick reference chart is provided for dealer diagnosing.
22-02-92
4/6/92
89 - 92 (AD)
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.
CATEGORY 23
BODY
TSB #
MODELS
SUBJECT/DESCRIPTION
23-04-95
2/10/95
94 - 95 (BR)
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.
23-29-95
6/9/95
94 - 95 (BR)
Cracked sunvisor support bracket/retainer.

The bulletin involves the replacement of the visor bracket with a revised bracket.
23-43-95
6/14/95
94 - 95 (BR)
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.
23-52-95 A
94 - 95 (BR)
Standard cab only
Creaking noise or exterior noise from back of cab.

The condition is a sheet metal creaking or exterior noise from the back of the cab caused by verticle
or horizontal cracks in cab back. Using a hoist and a strong light, look for cracks on lower portion of
cab. If cracks are noted four cab reinforcements and replacement cab isolators should be installed.
23-74-95
12/8/95
95 -96 (BR)
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.
23-08-94
1/28/94
94 (BR)
Wind noise at front of door.

Inspect the vehicle for the appropriate seal. If not present, perform the repair/installation procedure.
23-32-94
4/1/94
94 (BR)
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.
12
CATEGORY 23
BODYcontinued
23-36-94
4/22/94
94 (BR)
Front door to windshield moulding squeak/creak.

A noise from the front of door/plastic windshield moulding can occur. The correction is to install
anti-friction tape to the inside edge of the doors.
23-39-94
5/6/94
94 (BR)
Pickup box floor rattle.

The bulletin involves applying sealer to the pickup box floor at the crossmember.
23-40-94 A 94 (BR)
5/6/94
Door glass rattle.

If the door glass rattles when the door is closed and the window is open the bulletin describes the
diagnosis and repair of the weather strips.
23-41-94
5/13/94
94 (BR)
Creak noise from instrument panel bezel.

If a creaking noise occurs, coming from the instrument panel bezel, add felt tape to dash to dampen/
isolate the components.
23-45-94
6/3/94
94 (BR)
Snapping noise at right side of instrument panel.

A snapping noise (sounds like a small stone hitting the window) may occur. If diagnosed, add a
pad to the stiffening rib of the instrument panel to isolate the components.
23-49-94
7/1/94
94 (BR)
Warped tailgate.
Vehicles built at the Warren truck assembly plant (Dodge City complex) between 1/10/94 and
2/15/94 are suspect. Inspect as tailgate may be twisted or warped on the right side. Check the
run number for date of production. Check the last three digits as 02X through 05X are suspect.
Replace as necessary.
23-51-94
7/1/94
94 (BR)
Tailgate rattle.
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
8/12/94
94 (BR)
Popping or snapping noise from windshield.

The condition is a noise from the base of the windshield while traveling over rough roads/irregular
surfaces. The repair involves removing windshield spacers at the base of the windshield.
23-63-94
8/26/94
89 - 93 (AD)
Cowl cracks.
The condition is cracking or popping sounds from the cowl area at the lower corners of the
windshield. Inspect the area underneath the fender at the cowl welds. The fenders must be
removed to see the cracks. The repair involves installing cowl reinforcement brackets to the cowl.
23-68-94
9/30/94
94 - 95 (BR)
Glue seeps out at backlight or windshield moulding.

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.
23-71-94
10/7/94
95 (BR)
Tailgate latch handle loose.

The bulletin applies to vehicles built from 8/30/94 to 9/8/94. The hole in the tailgate was stamped
oversize. Inspect the latch handle and apply Mopar Bond-All Gel Adhesive to correct.
23-73-94
10/7/94
94 (BR)
Cup holder rattle.

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)
12/30/94
23-98-94
12/23/94
94 (BR)
Front seat cover wear through above the recliner pivot.

The condition is wear-through at the recliner pivot. Inspect as directed and repair if necessary.
Tailgate hard to latch in cold temperatures.
If the tailgate is difficult to latch when ambient temperatures are below freezing, the strikers should
be checked for proper adjustment. If the problem persist, replace the caliper stop with a shorter
one, part number 55075773.
13
CATEGORY 23
BODYcontinued
23-101-94
12/30/94
94 - 95 (BR)
Anti-friction tape on A-pillar.

Bulletin 23-36-94 described a squeak and paint abrasion at the door to windshield A-pillar area.
Anti-friction tape is now being applied at the assembly plants to prevent the problem. Do not
remove the anti-friction tape.
23-57-93
10/8/93
94 (BR)
Instrument panel creak.

A creak or squeak may be present on the left side of the instrument panel. The repair involves
loosening of the instrument panel to provide additional clearance between the cowl side panel
and instrument panel support joint.
23-64-93
11/19/93
94 (BR)
Tailgate rattles.
If tailgate rattles over bumps, check for looseness. If tailgate does not close tightly, replace the
overslam and alignment bumpers.
23-21-92
9/8/92
93 (AD)
93 standard paint colors.
23-09-91
8/26/91
92 (AD)
23-12-90
10/8/90
91 (AD)
23-24-89
10/10/89
90 (AD)
23-08-89
4/10/89
89 (AD)
CATEGORY 24
AIR CONDITIONING
TSB #
MODELS
SUBJECT/DESCRIPTION
24-01-95 A
3/3/95
89 - 94 (AD)
R-12 to R-134a refigerant adaptation procedure.

The bulletin describes the conversion from R-12 to R-134a. The procedure should only be
performed on vehicles when R-12 is no longer available.
24-06-95 A 94 - 95 (BR)
5/26/95
Odor from air conditioning ducts.

Some vehicles may emit a musty odor from the airconditioning ducts. The odor is most noticable
when the A/C system is first turned on. Two possible causes are discussed and repair procedure
are outlined based on less than or greater than 12 months in service.
24-08-95
5/19/95
94 - 95 (BR)
White flakes from instrument panel outlet.

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 on. The bulletin is issued for
information only.
24-08-94
5/6/94
94 (BR)
A/C evaporator odor.

A musty odor may be emitted from the air conditioner ducts. The odor is most noticeable when
the A/C is first turned on after the system has been left off evernight or longer. The odor is a
result of foreign material accumulating in the evaporator area. The bulletin involves cleaning and
disinfecting the A/C evaporator and housing.
14
CATEGORY 24
24-17-94
11/18/94
AIR CONDITIONINGcontinued
91 - 93 (AD)
94 - 95 (BR)
A/C evaporation freeze-up or lack of cooling on cycling clutch of air conditioning system.
Loss of A/C airflow and/or cooling while the blower fan continues to operate may occur. This bulletin
discusses the role of the powertrain control module in the A/C system.
The electrical signal from the A/C cycling clutch switch passes through the Powertrain Control
Module (PCM) to engage and disengage the A/C clutch relay. If the PCM is not properly disengaging
the A/C clutch via the relay, the compressor will stay on continuously and result in evaporator
freeze-up. Also, the PCM may not energize the A/C clutch relay at all. This condition results in the
lack of cooling from the A/C system.
The PCM should 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 important to perform the complete test sequence
because there are other A.C clutch relay circuit components that could also cause or contribute
to the condition.
24-27-93
11/19/93
91 -93 (AD)
94 BR
CATEGORY 26
Air conditioner compressor noise.

A growling noise may be heard with the compressor running. Diagnose the condition as outlined
and perform the repair procedure if necessary. The repair involves installing a revised compressor
valve plate assembly.
MISCELLANEOUS
TSB #
MODELS
SUBJECT/DESCRIPTION
26-04-94
10/28/94
All
Diagnostic procedure manuals.

The bulletin gives a current list of available diagnostic procedure manuals. These manuals provide
system information, step-by-step trouble shooting procedures, diagnostic and driveability tests,
along with diagrams, illustrations and helpful charts to find and fix problems on Chrysler Corporation
vehicles. These manuals can be ordered by calling 1-800-626-1523.
15
TSBs Issued During 1996

CATEGORY 2
FRONT SUSPENSION
TSB#
MODELS
SUBJECT/DESCRIPTION
02-01-96A
5/31/96
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 mounted camper. A rear stabilizer bar and auxiliary spring
comprise the kit.
02-03-96
5/31/96
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.
02-04-96
6/21/96
94-96 (BR)
Two wheel drive
(2WD)
Lower ball joint replacement.

This bulletin applies only to two wheel drive vehicles. It discusses the service differences in tack
welded ball joints/control arms and non tack welded ball joints/control arms.
02-06-96
11/29/96
94-97 (BR)
4x4 only
Track bar ball joint diagnosis.

The bulletin refers to the 97 Truck Service Manual and is a supplement to help the technician
troubleshoot loose or worn steering components. The track bar ball joint previously did not have
an inspection procedure.
CATEGORY 3
REAR AXLE
TSB#
MODELS
SUBJECT/DESCRIPTION
03-02-96
5/10/96
94-96 (BR)
2500 and 3500 4x2
trucks, regular cab,
automatic transmission
and two-piece propeller
shafts.
Shudder when pulling away from stop when operated at maximum GVW rating.
The bulletin is a supersession of bulletin 16-01-94. If the vehicle exhibits a driveline shudder while
pulling away from a stop at maximum GVW rating, the bulletin describes the replacement of the
two-piece driveline and center support bracket with a single piece assembly.
03-03-96
8/16/96
94-96 (BR)
With automatic
transmission and 5.9
Turbo Diesel engine.
Note: 96 2500 club
cab, 155 WB 4x4 with
heavy duty transfer
case built after 5/9/96
have the revised
propeller shaft.
Droaning noise/vibration.
The symptom typically occurs at maximum load and is engine speed specific - 1900 rpm for 4x2
models, 1850 rpm for 4x4 models with the truck in fourth gear and the torque converter clutch
locked up. If the problem is identified, a repair procedure involving a revised propeller shaft with
a yoke weight damper is described.
16
CATEGORY 5
BRAKES
TSB#
MODELS
SUBJECT/DESCRIPTION
05-14-95 A
2/9/96
95 - 96 (BR)
Brake pedal noise when depressed.

The symptom is a squawk type noise when the brakes are depressed. The repair involves installing
a revised back-up plate into the brake combination valve.
05-02-96 A
11/15/96
94-97 (BR)
2500, 8800 GVW sales code and 3500
built before 8/5/96
Accelerated brake lining wear, front versus rear.

The bulletin supersedes TSB 05-02-96 dated 2/23/96. The bulletin adds the 3500 series truck
and incorporates the use of revised brake linings. The bulletin discusses wear conditions. The
repair procedure involves replacing possibly the front brake linings, rear brake linings, or rear
wheel cylinders, depending on truck model and vehicle sales code.
05-08-96
9/13/96
94-96 (BR)
Brake pedal rattle.

If a rattle is heard coming from the brake pedal area and is eliminated when pressure is applied
to the side of the brake pedal, a repair procedure involving a wave washer is outlined.
05-09-96
10/4/96
All
Brake noise.
The information only bulletin describes the normal noises that may occur with a properly operating
system, ABS self check, trace squeak, grinding, groaning etc., noises are discussed.
05-10-96
12/13/96
94-97 (BR)
Chassis dynamics diagnosis.

The bulletin discusses conditions where-by the vehicle may move to the right or left when not
controlled by the driver. Several causes are cited (aftermarket wheels, road crown, cross winds,
incorrect tire pressures, worn wheel bearings, etc.). Diagnosis involves testing the vehicle
to determine if the drift is brake related. A brake system evaluation is outlined. Steering and
suspension inspection is discussed. Suspension torque values for fasteners are discussed. A
suspension geometry evaluation is outlined. Front end alignment specifications are provided.
Wheel shim kits and installation of shims for 4x4 trucks is discussed.
CATEGORY 8
ELECTRICAL
TSB#
MODELS
SUBJECT/DESCRIPTION
08-20-96
7/19/96
96-97 (BR)
Cassette auto load error on RAS code radio.

This information only bulletin describes a condition where the radio may enter the cassette play
mode without a cassette being inserted. The bulletin explains the correction and discusses the
function of the Ignition Off Draw (IOD) fuse.
08-21-96A
10/18/96
96 (BR)
Wiring harness connector repair packages.

This information only bulletin helps the service technician by providing a part number listing for the
correct electrical components per an assembly. It also gives a review of the diagnosis procedure
for electrical components.
08-23-96
8/23/96
94-96 (BR)
built prior to 12/15/96
Clicking noise from speedometer.

If a clicking/ticking noise is heard coming from the instrument cluster area, the bulletin describes
the repair procedure to replace the speedometer.
08-33-96
10/11/96
94-97 (BR)
Trailer tow wiring information.

Chrysler Corporation has offered optional trailer tow packages on all 94 through 97 Dodge Ram
Trucks and has made trailer tow packages available through Mopar for vehicles that were not
built with the trailer tow package. Several changes to the trailer tow wiring have occurred since
the truck was introduced. It also identifies flashers. This bulletin identifies the part numbers for
the Mopar trailer tow packages required to adapt trailer wiring to a vehicle that did not have the
trailer tow package installed as original equipment from the factory.
08-47-96
12/20/96
97 (BR)
Radio interference from buzzer module.

The condition is a buzzing noise in the rear radio speakers with the radio on/ignition on and the
door ajar. If a buzzing noise is heard the repair involves replacing the buzzer module.
17
CATEGORY 9
ENGINE
TSB#
MODELS
SUBJECT/DESCRIPTION
09-07-96
6/7/96
94-95 (BR)
Fuel injection pump oil supply bushing oil seepage.

If oil seepage is diagnosed, the bulletin describes the repair procedure using a special oil supply
and removal tool.
CATEGORY 11
EXHAUST
TSB#
MODELS
SUBJECT/DESCRIPTION
11-05-96
8/23/96
94-97 (BR)
Diesel turbocharger diagnostic procedure.

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
8/2/96
94-96 (BR)
Low pressure fuel system diagnostic procedures.

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
3/22/96
96 (BR)
Revised injection pump timing specifications.

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 10
STEERING
TSB#
MODELS
SUBJECT/DESCRIPTION
19-01-96
2/9/96
95-96 (BR)
Clunk or rattle felt in steering column/wheel.

The condition is a clunk or rattle in the steering wheel/column during slow turns or stops on some
95-96 trucks. Diagnosis includes a check of all fasteners for the appropriate torque value.
19-05-96
8/30/96
94-96 (BR)
4x4 trucks with sales
codes Z8A and Z8B
and 4x2 cab chassis
(Z3B) built before
5/15/96.
Shimmy after striking a bump or pothole.

This bulletin supersedes TSB 19-04-95 (5/12/95). The bulletin discusses a sustaining vibration
(shimmy) felt in the front end of the vehicle after striking a bump or pothole. The repair procedure
involves replacing the steering damper, replacing the track bar (if necessary) and the addition of
an auxiliary steering damper.
18
CATEGORY 19
STEERINGcontinued
TSB#
MODELS
SUBJECT/DESCRIPTION
21-04-96
3/15/96
96 (BR)
Transmission will not upshift following a 3-2 downshift.

Under certain conditions the transmission will not upshift following a 3-2 downshift. In this condition,
the engine will continue to operate at maximum governor speed in second gear until the throttle
is reduced. The condition only occurs if the overdrive is off. The repair involves reprogramming
the powertrain control module with new software.
21-13-96
9/20/96
96 (BR)
4x4
Transfer case shifter buzz or clatter.

A buzz or clatter may be heard from the 4x4 shifter at an engine speed of approximately 2000
rpm. The repair involves the addition of an insulating plastic gate liner to the transfer case shifter.
21-15-96
11/8/96
95-97 (BR)
Quick connect removal and reconnect procedure.

The information only bulletin describes the repair procedure for removal/reconnect of the
transmission cooler line fitting on trucks built after 3/20/95 and superseded bulletin 21-02-95,
3/31/95.
CATEGORY 23
BODY
TSB#
MODELS
SUBJECT/DESCRIPTION
23-01-96
1/5/96
94-96 (BR)
Replacement cargo box information.

This information bulletin list the revised part numbers for the 6.5 ft. and 8.0 ft. cargo box with a
reinforced front box floor.
23-02-96
1/19/96
94-96 (BR)
Creak or tick noise from right side instrument panel.

The noise can be reproduced by pushing on the instrument panel at the shelf above the glove box
door. The repair involves the removal of a 3/10 rivet.
23-09-96
2/2/96
96 (BR)
Clubcab with a J in
the VIN at position
11 and built prior to
10/6/95
Seatbelt buckle difficult to engage with one hand.

The driver side power seat may have a seat belt buckle that may be difficult to latch. The repair
involves replacement of the seatbelt buckle.
23-21-96
3/29/96
94-96 (BR)
Tailgate difficult to close in cold weather.

At less than 5 F the tailgate latch stop bumper may be too stiff to allow for easy closure. Inspect
and replace bumper stop.
23-27-96
4/19/96
96 (BR)
Windnoise (whistle) around grille area.

If vehicle exhibits a windnoise (whistle) at speeds of 45 to 85 mph the diagnosis involves checking
the grille for a manufacturing code CAV3. If there is not a CAV3 stamp than the grille is not
likely the source of the noise. If noise is from the grille, the repair involves adding 1/4 foam tape
between the grille and hood.
23-29-96
5/10/96
94-96 (BR)
Tailgate cracking on top inner ends.

Some vehicles may exhibit a sheet metal crack along the top inner ends of the tailgate. The bulletin
describes the parts and the correct repair procedure.
23-45-96
8/2/96
94-96 (BR)

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
8/2/96
94-96 (BR)
Rattle in door area.

Inspect the area of the door latch face around the lower window channel retaining bolt. If necessary
perform the outlined repair procedure.
19
CATEGORY 23
23-69-96
11/22/96
BODYcontinued
97 (BR)
Repair procedure for fallout/damaged paint.

Mopar Parts has released a new product, Mopar Fallout Removal Kit (p/n 04882417) for correcting
paint damage due to industrial fallout, rail dust, over-spray and volcanic ash.
The Mopar Fallout Removal Kit does not use a compounding process or acid wash and is the
current Chrysler preferred method for correcting fallout damage. This product uses a clay polymer
material and a liquid that are safer and better than other fallout removal methods.
CATEGORY 24
TSB#
AIR CONDITIONING
MODELS
124-01-96A 94-96 (BR)

10/18/96
SUBJECT/DESCRIPTION
Heater A/C system changes mode to defrost when accelerating.
This bulletin supersedes TSB 24-01-96 (2/2/96). The vacuum supply line to the Heater A/C system
may drop when accelerating or when speed control engages. This may cause the vacuum motor to
switch to defrost. The repair involves the addition of a vacuum check valve to the vacuum system.
24-12-96
8/2/96
96 (BR)
Water leaks from HVAC floor outlet onto floor.
Vehicles assembled
Water may drain out of the HVAC floor outlets while operating the A/C system. The bulletin
between 2/1/96 and
describes the diagnosis and repair procedure.
6/28/96 with a VIN
code 3 as the first digit.
24-16-96
10/11/96
95-96 (BR)
With engine serial
number 56230585 thru
56293178 or 45232867
thru 45360437. These
engines were installed
befor 6/1/96.
Vacuum system contaminated with engine oil.

Some Turbo Diesel trucks were produced without a check valve on the vacuum pump. Without a
check valve oil may enter the vacuum system. A visual inspection of the HVAC system is presented
and the repair procedure outlined.
YOU MIGHT BE A FORD/CHEVY OWNER IF...*

1. You write off a radiator as a business expense.
2. Your truck is insured by Smith & 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 I can take a bath.
6. You read the Auto Trader with a highlight pen.
7. Youve 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. Foxworthys Southern humor can be found at
bookstores everywhere. Buy his books for some serious fun.
20

CATEGORY 24
AIR CONDITIONING
TSB #
MODELS
SUBJECT/DESCRIPTION
02-03-97A
8/29/97
94-97 (BR)
Rear of vehicle sits too low.

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
3/17/97
94-97 (BR)

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
3/28/97
94-97 (BR)
2500-3500 series
Accelerated brake lining wear, front versus rear.

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
9/22/97
98 (BR)
Parking brake release handle does not fully return.

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
5/9/97
All
Engine coolant usage.

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
2/3/97
96-97 (BR)
JTEC powertrain control wiring harness connector repair packages.

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
5/23/97
94-97 (BR)
Engine failed to crankno start.

This information only bulletin discusses a condition where the engine does not crank over when
the ignition is placed in the start position. The shop should then refer to the appropriate 97 Service
Manual for proper diagnosis of the starter motors electrical circuit.
21
CATEGORY 8
ELECTRICALcontinued
08-22-97A
7/11/97
96-97 (BR)
Inoperative speed control.

This bulletin supersedes TSB 08-22-97, dated 6/20/97. The problem covered by the bulletin is
an inoperative speed control due to a vacuum supply hose that is loose, leaking or deteriorated.
Using the diagnosis as outlined in the 97 Service Manual determine the cause of the inoperative
speed control. Perform the repair as outlined in the bulletin.
08-27-97A
9/26/97
97 (BR)
Inoperative CD player as a part of sales code RAZ radio.

This bulletin supersedes TSB 08-27-97, dated 7/18/97. The bulletin applies to 97 vehicles equipped
with an AM/FM/cassette/CD player, sales code RAZ radio. A condition is described where the
CD player may become inoperative, and will not accept the CD when attempting to insert the
disk into the radio. The condition can be intermittent and may occur more often in hotter ambient
temperatures. The AM/FM radio and cassette portion of the radio will continue to operate normally.
The repair involves an exchange of the unit as supplied by Chryslers repair center.
08-30-97
9/5/97
98 (BR)
Ashtray receiver lamp degrades from blue-green to bright white.

The ash receiver lamp, when illuminated, may change from a blue-green illumination to a bright
white illumination. This change will occur over a long period of time of continuous use. This bulletin
involves replacing the ash receiver lamp and housing with revised parts.
08-32-97
9/19/97
94-98 (BR)
NHTSA authorized airbag deactivation for medical necessity.

This information only bulletin describes the procedures necessary to deactivate airbags authorized
by NHTSA. Airbag deactivation is a customer pay procedure, not covered under the provisions
of warranty.
08-35-97
9/26/97
98 (BR)
Dead battery from ignition off draw (IOD).

The problem described is a dead battery due to the glove box lamp remaining illuminated when
the glove 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
11/28/97
98 (BR)
Remote keyless entry transmitter batteries discharge prematurely.

This bulletin applies to vehicles built prior to August 15, 97 and describes a condition where the
Remote Keyless Entry transmitter batteries discharge in approximately 6 weeks. The repair calls
for replacement and reprogramming of the transmitter.
CATEGORY 11
EXHAUST
TSB #
MODELS
SUBJECT/DESCRIPTION
11-01-97
5/16/97
94-97 (BR)
Whine or howl while driving at highway speeds.

This bulletin applies to vehicles equipped with the diesel engine option. Some vehicles may
experience a whine or howl noise while driving at highway speeds. This noise may be missinterpreted as turbo whine. After proper diagnosis of the condition the bulletins repair procedure
involves replacement of the muffler.
CATEGORY 14
FUEL
TSB #
MODELS
SUBJECT/DESCRIPTION
14-07-97
7/18/97
94-97 (BR)
Diesel fuel injection pump tampering.

This information only bulletin applies to inline fuel injection pumps as found on 94 thru early 98
model trucks. The bulletin stipulates that there are only a few items on the pump that are serviceable
(low idle adjustment, timing adjustment, 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.
22
CATEGORY 18
VEHICLE PERFORMANCE
TSB #
MODELS
SUBJECT/DESCRIPTION
18-25-97
8/15/97
96-97 (BR)
EGR system failure with Hex Code $2E* on 5.9L Diesel.

This bulletin applies to vehicles equipped with a 5.9L Cummins Diesel engine built between Jan.
1, 1996 and Dec. 31, 1996 with California emissions sales code NAE. If while performing other
diagnostics, the technician notices Hex Code $2E - EGR SYSTEM FAILURE on the Diagnostic
Scan Tool (DRB III) the diagnosis outlined in the bulletin should be followed. The customer may or
may not experience any engine driveability symptoms. The Malfunction Indicator Lamp (MIL) will
not be illuminated. The repair involves using revised test procedures to diagnose the EGR system
and selectively erase and reprogram the Powertrain Control Module (PCM) with new software
(calibration changes) for the condition listed.
*Editors note: $2E is correct.
18-29-97A
12/5/97
96-98 (BR)
with Cummins engine
and five-speed
transmission
CATEGORY 19
Vehicle bucking on 96 thru 98 trucks with the Cummins engine and a manual transmission.
This bulletin supersedes TSB 18-29-97, dated 10/17/97. The condition to be corrected is one
where the vehicle may exhibit a bucking or jerking condition while under light acceleration or
while driving at steady state speeds. The vehicle may be in a loaded or unloaded state when the
bucking or jerking occurs. This condition results from the sensitivity of the throttle linkage to driver
input. The repair procedure involves replacement of the throttle linkage levers with revised parts.
STEERING
TSB #
MODELS
SUBJECT/DESCRIPTION
19-08-97
5/30/97
96-97 (BR)
Clunk/rattle felt in steering column/wheel.

This bulletin supersedes TSB 19-01-96, dated 2/9/96 for 1996 model year vehicles. This bulletin
applies to all vehicles built in the United States (first digit of VIN = 1) and vehicles built in Mexico
(first digit of VIN = 3) before Mar. 3, 1997. The condition to be examined is a clunk or rattle that
maybe felt in the steering wheel/column during slow turns, rough road driving, and stops. The
diagnosis involves inspection of the front suspension and steering components, including a check of
all fasteners for proper torque as specified in the appropriate Service Manual. The repair procedure
involves replacement of the steering intermediate shaft.
19-10-97
8/15/97
94-98 (BR)
Steering wander.
If when driving on a straight road, a higher than normal steering wheel movement (perceived as
excessive play) is required to keep the vehicle going straight or if over-compensating the 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
11/28/97
94-97 (BR)
Lower steering column noise and/or minor lower steering column movement.
This bulletin applies to vehicles built before Dec. 31, 1996 and describes a lower steering column
noise and/or minor lower steering column movement. If movement in the steering column is greater
than the tolerance, the repair involves adding a toe plate (shim) to the steering column.
CATEGORY 21
TRANSMISSION
TSB #
MODELS
SUBJECT/DESCRIPTION
21-12-97
8/29/97
96-97 (BR)
Transfer case shifter buzz or rattle.

This bulletin supersedes TSB 21-13-96, dated 9/20/96. A buzz or clatter may be heard from the
4x4 transfer case shifter at an engine speed of approximately 2000 rpm. The condition may worsen
when the engine is under load. On vehicles equipped with automatic transmission the diagnosis
must be done with the transmission in overdrive and torque converter clutch engaged. If necessary
the correction involves bending the shift lever spring reaction tab outward to increase the spring
tension on the shift lever.
23
CATEGORY 22
WHEELS & TIRES
TSB #
MODELS
SUBJECT/DESCRIPTION
22-01-97
6/13/97
94-97 (BR)
Tire and wheel runout.

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.
CATEGORY 23
BODY
TSB #
MODELS
SUBJECT/DESCRIPTION
23-03-97
2/14/97
89-93 (AD)
94-97 (BR)
Difficult to clean light colored chalky residue from black plastic body components.
The discussion covers difficult to clean light colored chalky residue from exterior plastic body
components that are molded in black, especially those that are textured, such as door handles,
mirrors, roof rack attachments, etc. Frequently, this chalky residue is actually an accumulation
of car wax, road grime, etc. trapped in the plastic grain. The correction is to clean the component
with a soft bristle brush and mild detergent (liquid dish soap) until the residue is gone.
23-22-97
4/4/97
94-97 (BR)
Drivers side wiper blade contacts A-Pillar.

This bulletin applies to vehicles built before Oct. 15, 1996. If the drivers side wiper blade contacts
A-Pillar or a popping sound can be heard when the drivers 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
5/2/97
96-97 (BR)
Windnoise (whistle) around grille area.

This bulletin supersedes TSB 23-27-96, dated 4/19/96. Vehicles may exhibit a condition where a
windnoise whistle occurs from the front of the vehicle. This condition can occur while driving the
vehicle at highway speeds between 45-65 mph or at slower speeds when driving into a headwind.
If necessary a foam strip is installed between the grille and hood.
23-27-97
5/9/97
94-97 (BR)
Water leaking through rear window.

The problem is water leaking past rear window module into cab of vehicle. The bulletin outlines
the repair procedure.
23-39-97
6/27/97
94-97 (BR)
Driver side power mirror vibrates while driving.

This bulletin supersedes TSB 08-64-94, dated 11/4/94. The condition covered in the bulletin is
one where the driver side power mirror vibrates causing blurred images in driver side mirror while
driving. The repair involves installing a power mirror support bracket onto the drivers side mirror
23-61-97
11/28/97
94-98 (BR)
Noise coming from cargo box area.

The problem is an oil canning noise complaint coming from the box area caused by the cargo
box cross member contacting the vehicles 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
12/6/97
98 (BR)
Upper rear corner of front door contacts upper front corner of cargo door.
This bulletin applies to Quad Cab Ram trucks and describes a door closing condition where the
upper rear corner of the front door may come in contact with the upper front corner of the cargo
door, causing the paint to chip off the front and/or cargo door. If such, the correction is the installation
of an anti chip plastic molding over the chipped area.
23-68-97
12/19/97
98 (BR)
Water leaking into vehicle through side cowl panel.

This bulletin applies to vehicles built between November 16, 1997 and November 26, 1997. If
water leaks through either the right and/or left side cowl panels and dampens the carpet in the
foot well area, a trim cover is removed and a water proof patch is installed over the cowl panel.
24
CATEGORY 24
AIR CONDITIONING
TSB #
MODELS
SUBJECT/DESCRIPTION
24-11-97
7/11/97
94-98 (BR)
A/C evaporator odor.

This bulletin supersedes technical service bulletin 24-06-95A, dated 5/26/95. Some vehicle
operators may experience a musty odor from the A/C system, primarily at start up in hot and humid
climates. This odor may be the result of microbial growth on the evaporator core. During normal
A/C system operation, condensation forms in and around the A/C evaporator. When airborne
pollutants mix with this condensation, bacteria and fungi growth begins and odor results. The
repair involves cleaning the evaporator with Mopar aerosol cleaner.
25

CATEGORY 5
BRAKES
TSB #
MODELS
SUBJECT/DESCRIPTION
05-04-98
6/12/98
97 - 99 (BR)
Height sensing proportioning valve removal.

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
6/19/98
97 - 98 (BR)
Release fork orientation.

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
12/11/98
98 - 99 (BR)
Diesel engine overheating.

This information applies to vehicles equipped with a 24 valve Cummins diesel engine with an
engine serial number (ESN) 56512007 or prior. This bulletin involves replacing the thermostat
with a revised part (05015090AA).
CATEGORY 8
ELECTRICAL
TSB #
MODELS
SUBJECT/DESCRIPTION
08-09-98
3/13/98
94 - 98 (BR)
Driver side power mirror vibrates while driving.

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
3/13/98
98 (BR)
Delayed operation of fog lamps.

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
3/27/98
98 (BR)
Headlamp switch knob pulls out of headlamp switch.

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.
26
CATEGORY 8
08-14-98
3/27/98
ELECTRICALcontinued
98 (BR)
Clicking, rattling, or ratcheting noise coming from the seat belt retractor.
This bulletin applies to all club cab vehicles (both two door Club Cab and Quad Cab models)
built before March, 5, 1998. During normal operation, the seat belt retractor on the vehicles
listed above may emit a clicking, rattling, or ratcheting noise. This noise may be caused by
a solenoid that is energized and de-energized to operate the retractor spool of the seat belt
retractor assembly. The solenoid is controlled by a Seatbelt Control Timer Module (SCTM) which
unlocks the retractor when energized.
If your diagnosis determines and the owner feels that the noise occurs too frequently, the SCTM
on your vehicle may be too sensitive and should be replaced.
08-16-98
4/17/98
89 - 93 (AD)
94 - 99 (BR)
Installation of radio transmitting equipment.

This bulletin supersedes technical service bulletin 08-22-95, dated May 12, 1995. This
information-only TSB is provided to assist in properly installing communication equipment in
Chrysler vehicle. This information should be given to any owner inquiring about installing radio
transmitting equipment.
08-17-98
Rev. C
12/30/98
94 - 99 (BR)
Airbag on-off switches.

This bulletin supersedes technical service bulletin 08-17-98 Rev. B dated September 18, 1998.
This information only bulletin is provided to identify the parts and procedures necessary to
deactivate airbags authorized by NHTSA. Airbag deactivation is a customer pay procedure.
08-21-98
5/22/98
98 (BR)
Radio Interference to/from two-way radio receivers.

Customers may complain of intermittent poor reception on their two-way radios. This condition
does not affect the operation of any AM or FM band radio. Radio receivers from approximately 20
MHZ to 174 MHZ may be susceptible to Radio Frequency Interference (RFI) from the fuel pump
modules motor. If there is RFI, the bulletin describes the installation of an RFI filter in series with
the electric fuel pump.
08-35-98
6/24/98
98 (BR)
Instrument cluster bezel breaks when removed.

This information-only bulletin is a reminder that the instrument cluster bezel is retained by
several snap clip retainers and one screw located underneath the power outlet access door. It is
imperative that this singular screw is removed prior to attempting to remove the instrument cluster
bezel from the instrument cluster.
08-36-98
6/24/98
89 - 93 (AD)
94 - 99 (BR)
Use of two digit calendar year codes in automotive computers.

There has been a great deal of recent media attention regarding the turn of the century (year
2000, Y2K, etc.) and the effect it will have on computers that have used two-digit calendar year
coding in their programming. Questions are arising regarding computers used in automotive
applications and the effect year 2000 will have on them.
Two digit calendar-year codes have not been used in any Chrysler automotive onboard
applications and no problems related to use of two digit coding for calendar years are anticipated.
08-51-98
11/27/98
99 (BR)
Compass mini trip computer indicates erroneous average miles per gallon, distance to empty,
and/or trip odometer.
This bulletin applies to vehicles equipped with the compass mini trip computer (sales code CUS).
The display will show an erroneous number in the third digit from the right. If repair is necessary,
the module is replaced.
08-54-98
12/30/98
99 (BR)
Static inside speakers and/or side speaker cuts out when power outside mirror operates.
This bulletin applies to vehicles equipped with the power audio amplifier (sales code RDE) and
heated outside power mirrors (sales code GTS) built between September 7, 1998 and November
3, 1998. The problem discussed is that static can be heard in the side speakers and/or the sound
coming from the side speakers can cut out and/or in extreme cases, the radio can cut out with the
radio in the FM mode when the power mirror is actuated to its end of travel. The repair involves
replacing the mirrors.
27
CATEGORY 9
ENGINE
TSB #
MODELS
SUBJECT/DESCRIPTION
09-06-98
10/30/98
98 (BR)
Incorrect engine oil dipstick.

This information applies to vehicles equipped with 24 valve Cummins diesel engines. Some
early 1998 24 valve diesel engines were built with an incorrect dipstick calibration. This incorrect
marking causes an overfilled condition of approximately 1 1/2 quarts when at the top end of the
safe zone on the dipstick. This overfill condition is not damaging to the engine. The Cummins
part number is stamped on the 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
9/25/98
94 - 98 (BR)
Turbo Diesel wastegate actuator repair kit.

A new kit has been released that will allow technicians to repair turbochargers with failed
wastegate actuators.
CATEGORY 14
FUEL
TSB #
MODELS
SUBJECT/DESCRIPTION
14-01-98
Rev. A
7/17/98
98 (BR)
High pressure fuel line service.

This bulletin supersedes technical service bulletin 14-01-98 dated March 6, 1998. This information
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
3/27/98
98 (BR)
Fuel filter requirements.

With the introduction of the Cummins 24 valve electronically injected engine, a new VP44 injection
pump was also introduced. The VP44 injection pump requires finer fuel filtration due to tighter
tolerances within the pump. Whenever a fuel filter is replaced, make sure the replacement filter is
part number 04883963AB/Cummins 3931476/Fleetguard FS19528.
14-04-98
5/8/98
98 (BR)
Accelerator pedal buzzing noise with cruise control engaged.

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
2/27/98
94 - 98 (BR)
Hard starting diagnosis.

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
2/27/98
94 - 98 (BR)
Effects of incorrect idle speed.

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.
28
CATEGORY 21
TRANSMISSION
TSB #
MODELS
SUBJECT/DESCRIPTION
21-10-98
Rev. A
9/25/98
94 - 99 (BR)
Loss of fifth gear.

This bulletin supersedes technical service bulletin 21-10-98, with an effective date of September
11, 1998. This bulletin applies to vehicles equipped with a NV 4500 manual transmission and
the 8.0L V10 gas engine or the 5.9L 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
5/8/98
98 (BR)
Rear sliding window difficult to open, will not remain latched, and/or leaks water past the lower
run channel.
If the rear sliding window is difficult to open, will not latch, and/or leaks water past the sliding rear
windows lower run channel, this bulletin describes the proper diagnosis/repair.
23-16-98
5/1/98
98 (BR)
Splash guards (mud flaps) discolored and/or distorted due to proximity to tailpipe.
This bulletin applies to vehicles equipped with dual rear wheels. Vehicles equipped with splash
guards may experience discoloration and/or distortion along the outside edge of the passenger
side rear splash guard due to the proximity to the tailpipe. If necessary, a new tailpipe assembly
is installed.
23-17-98
5/1/98
94 - 98 (BR)
Center armrest driver side hinge cover broken.

If the center armrest upper inertia latch cover (driver side hinge cover) is broken, the proper repair
involves replacement of the hinge.
23-35-98
8/7/98
94 - 99 (BR)
Door trim panel retainer clip attachment breakage when door trim panel is removed for service.
The bulletin cautions the dealer that damage to the door trim panel may occur if the door trim
panel retainer clips are separated from the door without using a trim panel removing tool.
23-37-98
8/21/98
98 - 99 (BR)
Cargo net eliminated from production.

This bulletin applies to standard cab vehicles and informs the dealer network that the cargo net
is no longer a production item. It can be purchased through the parts department using Mopar
number 04761197.
23-58-98
11/27/98
99 (BR)
Wind noise (whistle) around grill area and/or dimples on the grill painted surface opposite of the
grill fasteners.
This bulletin applies to Ram trucks equipped with the sport package. If there is a windnoise
whistle occurring from the front of the vehicle at highway speeds between 45-65 mph or at slower
speeds when driving into a headwind, this bulletin describes the repair procedure.
29

CATEGORY 2
FRONT SUSPENSION
TSB#
MODEL
SUBJECT/DESCRIPTION
02-06-99
Rev. A
12/17/99
94-00 (BR)
Front wheel bearing grease is evident on the bearing seal area.

This bulletin supersedes TSB 02-06-99, dated June 11, 1999. The revisions include the addition
of 4x2 models and additional model years. This information-only bulletin discusses the fact that
front wheel bearings may be incorrectly diagnosed as faulty due to the evidence of wheel bearing
grease on the bearing seal areas. This grease purge is a normal design condition. The factory
fill of the bearings includes a slightly greater amount of grease than is required for the bearing
lifetime lubricant. A portion of the grease purges through the self-venting seal in the initial few
thousand miles to form an additional barrier in the area of the seal and the stamped slinger. This
barrier aids in the prevention of contaminants passing through the seal and into the bearing.
Do not remove or clean the purged grease as part of normal maintenance because it provides
additional protection and once removed, damage to the seal and bearing could result.
02-13-99
09/10/99
94 - 99 (BR)
Squeaking noise from rear leaf springs.

This bulletin supersedes TSB 02-03-96, dated may 31, 1996. If the diagnosed condition is a
squeaking noise coming from the rear of the vehicle, the bulletin gives the correct repair procedure
to replace the leaf spring tip liners/install spring clip isolators.
CATEGORY 5
BRAKES
TSB#
MODELS
SUBJECT/DESCRIPTION
05-04-99
05/28/99
98 - 99 (BR)

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,
aftermarket wheels, tires that have a belt that has shifted, incorrect tire pressure, a vehicle that
is carrying extra added weight (e.g. tool boxes), steering and/or suspension components that
are worn or damaged, wheel bearings that are worn or damaged, a vehicle that is not with in
alignment specifications, brake drag from brake components that do not release, or braking
imbalance.
Additionally, under certain road conditions (e.g. high road crown, grooved roads, etc.), most
vehicles will move to the right or left uncontrolled by the driver. Also, the same may happen if a
cross-wind condition exists.
05-11-99
12/31/99
30
94 - 96 (BR)
Revised power brake booster check valve.

This bulletin applies to vehicles equipped with the 5.9L Cummins diesel engine. A revised power
brake booster check valve p/n 05011393AA has been released for service. The new check valve
performance has been improved by changing the flapper style check valve to a spring loaded style
check valve. The spring loaded style check valve performance is superior, especially in vehicles
that utilize mechanical vacuum pumps to provide the vacuum source to operate the power brake
booster. Part number 05011393AA should be used any time the power brake booster check valve
is serviced on the subject model vehicles.
CATEGORY 8
ELECTRICAL
TSB#
MODELS
SUBJECT/DESCRIPTION
08-06-99
Rev. A
12/17/99
98 - 00 (BR)
Radio interference to/from two-way radio receivers.

This bulletin supersedes technical service bulletin 08-06-99, dated March 5, 1999. Customers
may complain of intermittent poor reception on their two-way radios. This bulletin involves
installing a RFI filter in series with the electric fuel pump motor.
08-16-99
6/11/99
99 (BR/BE)
Inoperative or intermittent remote keyless entry (RKE) transmitter.

This bulletin supersedes TSB 08-16-99, Dated May 28, 1999. This bulletin applies to vehicles
built prior to March 1, 1999. It applies only to vehicles equipped with the new peanut shaped
transmitters. The problem discussed is an inoperative RKE transmitter. This condition may be
intermittent and will have similar symptoms to a dead transmitter battery. This can be caused
by a lost or intermittent contact between the battery terminal and the printed circuit board. A
transmitter repair kit containing a new case with an improved battery terminal has been released.
This bulletin involves replacing the RKE transmitter case.
08-17-99
05/28/99
99 (BR)
Compass/mini-trip computers no longer need calibration during new vehicle preparation.

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 will still be necessary to set the variance of the compass prior
to vehicle retail delivery.
08-22-99
07/02/99
98 (BR)
Intermittent operation of oil pressure gauge.

This bulletin applies to vehicles equipped with the 5.9L Cummins 12-valve Turbo Diesel
engine built before January 5, 1998. The condition for correction is an oil pressure gauge that
intermittently drops to zero pressure. In addition, the warning chime may sound when the oil
pressure gauge drops to zero pressure and the check gauge lamp may come on. Proper repair
involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new
software (a calibration change).
08-28-99
08/20/99
00 (BR)
Simplified compass mini trip computer calibration.

This bulletin applies to vehicles equipped with the compass mini trip computer (sales code CUS).
The subject model vehicles are shipped from the assembly plants with the compass mini trip
computer NOT calibrated. This will be identified by CAL displayed on the compass mini trip
computer. To calibrate the compass mini trip computer, drive the vehicle in a complete circle until
CAL is no longer displayed on the compass mini trip computer.
08-32-99
10/01/99
98 - 99 (BR)
Radio interference to/from two-way radio receivers.

This bulletin addresses the complaint of intermittent poor reception on two-way radios, and
discusses the proper repair. Radio receivers from approximately 30 MHZ to 50 MHZ may be
susceptible to Radio Frequency Interference (RFI) from the Airbag Control Module (ACM).
Note: technical service bulletin 08-06-99, dated March 5, 1999, addresses two-way radio
interference from the fuel pump module and should be performed prior to performing this technical
service bulletin.
08-37-99
11/12/99
94 - 00 (BR)
Airbag On-Off Switches.

This bulletin supersedes technical service bulletin 08-17-98 Rev C, dated December 30, 1998.
This information-only bulletin identifies the parts and procedures necessary to deactivate airbags
authorized by NHTSA. Airbag deactivation is a customer pay procedure, NOT covered under the
provisions of the warranty.
08-39-99
12/10/99
00 (BR)
Communications may stop between the JTEC PCM and a generic scan tool.
This information applies to vehicles built before November 30, 1999. The JTEC Powertrain
Control Module (PCM) may stop communications with a generic scan tool. This bulletin involves
selectively erasing and reprogramming the JTEC PCM with new software calibration change
(00Cal13 & 00Cal13A).
31
CATEGORY 8
ELECTRICALcontinued
08-42-99
12/17/99
98 - 99 (BR)
The fuel gauge reads full for an excessive period of time.

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 module
sticking and may be difficult to diagnose. Perform the repair procedure (new fuel pump module) if
the customers concern matches the description identified in the Symptom/Condition.
08-43-99
12/17/99
98 - 99 (BR)
Central timer module software update when a wiper module is replaced.

This bulletin applies to vehicles equipped with remote keyless entry. Due to a design change
in MOPAR replacement wiper modules, the central timing module must be updated with new
software in order to allow the wiper module to function properly. The outlined repair procedure
must be performed any time the wiper module is replaced.
08-44-99
12/31/99
99 - 00 (BR)
Intermittent speaker operation/static.

This bulletin applies to vehicles equipped with the Infinity sound system sales codes (RBR, RBN,
and RAZ) built before October 1, 1999. The condition is intermittent operation/static that may
occur in any or all speakers. The bulletin describes the proper repair.
CATEGORY 9
ENGINE
TSB#
MODELS
SUBJECT/DESCRIPTION
09-04-99
07/16/99
98 - 99 (BR)
Hard-to-diagnose noise coming from the engine turbocharger area.

This bulletin applies to vehicles equipped with a Cummins 5.9L 24V diesel engine built prior to
engine serial number (ESN) 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 turbocharger bearing.
The sound of the noise may be described as a whistle, a squeal, a howl, a moan, or a gurgle. The
noise will be more noticeable as engine temperature increases. The noise will most often occur
when the warm engine is operated between 1,500 and 2,200 rpms. 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
02/19/99
98 - 99 (BR)
Erratic torque converter clutch (TCC) operation.

This information applies to vehicles equipped with a 5.9L 24-valve diesel engine and automatic
transmission built between January 1, 1998 and December 18, 1998. Some vehicles may exhibit
a surge-like condition while in fourth gear. This may be caused by the TTC unlocking and locking
when it should be consistently locked. The cause of this erratic operation has been identified
as electrical noise from the Throttle Position Sensor (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
04/30/99
98 - 99 (BR)
Erroneous MIL illumination with DTC $A8 (P1763) governor pressure sensor volts too high.
This information applies to vehicles equipped with a reseries automatic transmission built before
December 18, 1998. Some vehicles may exhibit a MIL illumination with DTC $A8 (P1763) GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH. The vehicle operator may experience
slower than normal accelerations because the transmission may temporarily enter third gear
Limp-In Mode. The Limp-In Mode may last until the vehicle owner cycles the ignition key. The
technician may not detect a problem with the automatic transmission during a diagnostic test
32
CATEGORY 18
VEHICLE PERFORMANCEcontinued
or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic
pressure is the result of a new valve body machining process. Vehicles built after January 1,
1998 have an automatic transmission with this new process valve body. Vehicles built before
January 1, 1998 may experience this condition if either the 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
04/30/99
98 - 99 (BR)
Improved speed control system sensitivity to set speed.

Some customers may complain that their vehicle speed control system may be too busy or drift
more than 2 mph below or above the initial vehicle set speed. Vehicle load and road/terrain
conditions may impact this issue. The new PCM software improves the speed control system
sensitivity so that the vehicle speed remains closer to its set speed with fewer engine rpm
oscillations. This bulletin involves selectively erasing and reprogramming the JTEC Powertrain
Control Module (PCM) with new software (calibration changes 98Cal12A, 99Cal 17). There is no
change to the Cummins CM551 Engine Control Module (ECM) software.
18-09-99
05/21/99
99 (BR)
Common diagnostic trouble codes caused by an open fuse.

Analysis has revealed an issue with repeated repairs for the same Diagnostic Trouble Code
(DTC). The DTC may be due to an overlooked open circuit used to power the component in
question. In most instances, either the circuit fuse has been erroneously removed or the fuse
itself is open (blown). The component in question, and its circuit, are often protected by two
fuses. It is usually the lower amperage fuse that is either missing or open. The lower amperage
fuse is positioned electrically in the circuit between the component in question and either a relay
or the ignition switch. The lower amperage fuse will be located either in the underhood Power
Distribution Center (PDC) or in the instrument panel Junction Block. The lower amperage fuse
is often missing because it was removed erroneously for use in another low current circuit. If
the lower amperage fuse is open (blown), then the circuit and component in question must be
checked for an electrical short. Check to make sure that the open fuse was not exchanged with
another fuse or was damaged by an installed accessory.
18-11-99
05/28/99
98 - 99 (BR)
Slow acceleration or lack of power while towing or hauling a heavy load.

This information applies to vehicles equipped with a 5.9L - 24V diesel engine built before engine
serial number 56587297 with a date of engine manufacture of May 5, 1999. This information is
available on the engine data plate, which is located on the left side of the engine, affixed to the
gear housing. There may be a condition of low power or slow acceleration when towing or when
hauling a heavy load. This software change, to the Cummins CM551 diesel engine controller, will
increase engine torque. Some 1998 BR vehicles equipped with a 5.9L - 24V diesel engine may
already have the latest software revision. Verify that the ECM is at calibration level 98T17 (p/ns
333034303J / 333035303J / 333036303J / 333037303J). 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 operator may complain of slow acceleration or a lack of power when towing or hauling
moderate to heavy loads. The condition may be worse at higher altitude. Do not proceed with this
technical service bulletin until TSB 18-11-99 has been performed. This bulletin further describes
diagnostic procedures that may be used to assist the technician in the diagnosis of a low power
or poor performance complaint.
18-24-99
11/15/99
00 (BR)
5.9L - 24V Cummins diesel low power or poor performance diagnostic.

The vehicle operator may complain of slow acceleration or a lack of power when towing or hauling
moderate to heavy loads. The condition may be worse at higher altitude. This bulletin involves
diagnostic procedures that may be used to assist the technician in the diagnosis of a low power
or poor performance complaint. The procedures outlined start with confirmation that TSB 18-1198 (turbocharger wastegate actuator repair kit) has been performed. Additionally, the technician
should verify that the throttle is opening fully.
Perform the complete FUEL TRANSFER PUMP PRESSURE TEST procedure.
33
CATEGORY 18
Inspect the fuel tank rollover valve for restrictions and to ensure that the shipping cap has not
been left on the end of the valve.
Inspect the charge air cooler hoses and clamps for proper installation. Inspect all connections
and clamps for looseness. Verify that no leaks are present when the engine is under boost
conditions.
While performing the following road test, verify that the turbo boost pressure is 16 psi during
wide open throttle (WOT) acceleration.
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
11/15/99
00 (BR)
CATEGORY 19
5.9L - 24V diesel engine intermittent engine stumble.

This information applies to vehicles equipped with a 5.9L - 24V diesel engine built before engine
serial number 56624822 with a date of manufacture of August 28, 1999. This information is
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 Engine Control Module (ECM)
software corrects this condition (calibration change 99CalT9A).
STEERING
TSB#
MODELS
SUBJECT/DESCRIPTION
19-03-99
05/07/99
94 - 99 (BR)
Steering slow to return to center.

This bulletin supersedes technical service bulletin 19-01-94, dated January 28, 1994. This bulletin
applies to 4x4 vehicles equipped with a Dana model 60 front axle (sales code DRD). The rate of
steering return to center (after turning a corner) may be slower than normal or may require slight
steering wheel correction while driving straight ahead. The repair involves performing a ball joint
tightening sequence.
19-04-99
05/28/99
99 (BR)
Steering system diagnosis.

Customers may complain that the steering system feels heavy or the steering wheel is not
centered while driving on a straight road. The steering gear used on the 1999 Ram Truck is
designed to have a heavy on-center steering characteristic. Before replacing a steering gear for
a steering system feel complaint, perform the suggested diagnosis to ensure that the rest of the
steering system components perform as designed.
CATEGORY 21
TRANSMISSION
TSB#
MODELS
SUBJECT/DESCRIPTION
21-08-99
04/30/99
96 - 99 (BR)
Buzz, whine or moaning-type noise from a cold transmission when reverse is selected.
Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is
selected. This noise has been described as a buzz, whining, or moaning-like noise. The noise
is most noticeable when transmission fluid temperature is below 100 degrees F (38C). The
condition is caused by a resonance of the transmission regulator valve system. The repair
involves replacing the transmission regulator valve.
21-14-99
11/05/99
00 (BR)
47RE transmission - harsh or early shifts.

This information applies to vehicles equipped with a 5.9L - 24V diesel engine and 47RE
automatic transmission built before engine serial number 56624822 with a date of manufacture
34
CATEGORY 21
of August 28, 1999. This information is available on the engine data plate, which is located on
the left side of the engine, affixed to the gear housing.
Some early-built 2000 model year Ram Trucks may experience a harsh 3-4 shift. This condition
may occur during any throttle position situation when transmission sump temperatures are 60
degrees F (15C) or higher. The harsh 3-4 shift may be more pronounced during heavy vehicle
loading, e.g., 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
11/12/99
99 - 00 (BR)
CATEGORY 23
47RE delayed TCC lock-up and/or MIL P1740 = TCC or O/D solenoid performance.
This information applies to vehicles built for the California market (NAE), equipped with a 5.9L
- 24V diesel engine and built between March 2, 1999 and October 1, 1999. The customer
may experience a delayed torque converter clutch engagement (lock-up). This condition may
illuminate the Malfunction Indicator Lamp (MIL) due to Diagnostic Trouble Code (DTC) P1740 TCC or O/D Solenoid Performance. In some situations, the customer may describe the condition
as a lack of a transmission shift (TCC lock-up) between 30 and 50 mph. The transmission valve
body upper housing separator plate was revised (wider slot) to improve fluid flow to the torque
converter clutch. This bulletin describes the replacement of the transmission valve body upper
housing separator plate.
BODY
TSB#
MODELS
SUBJECT/DESCRIPTION
23-08-99
03/05/99
94 - 99 (BR)

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
05/21/99
98 - 99 (BR)
Bezel comes loose from seat belt retractor cover.

This bulletin applies to club/quad cab vehicles. The seat belt retractor cover bezel comes loose
due to a cracked seat belt retractor cover. The crack may occur at the bottom of the opening
where the seat belt bezel snaps into the cover. This bulletin describes the installation of a new
seat belt retractor cover.
23-22-99
07/02/99
94 - 00 (BR)
Rattle in door area.

This bulletin supersedes technical service bulletin 23-46-96, dated August 2, 1996. Customers
may complain of one or more of the following symptoms: rattle heard in the door area; door
window shakes when closing; door lower window channel bolt has pulled through the door sheet
metal; door sheet metal is cracking around the lower window channel bolt. This bulletin involves
removing the window channel from the door and installing a revised window channel.
23-28-99
08/13/99
98 - 99 (BR)
Power seat track vertical adjustment stuck in a full upward or full downward position.
This bulletin applies to club or quad cab vehicles built before March 1, 1999. The repair condition
is that the front and/or rear power seat track vertical adjuster motors are stuck in a full upward or
full downward position. The repair involves removing existing lubrication on the power seat track
adjustment lead screws and then applying a new lubricant.
23-35-99
Rev. A
10/01/99
94 - 00 (BR)
Child seat tether anchors.

This bulletin supersedes technical service bulletin 23-35-99 dated September 3, 1999. This
bulletin identifies the parts and labor operation numbers necessary to install a child seat tether
anchor.
35

CATEGORY 2
FRONT SUSPENSION
TSB#
MODELS
SUBJECT/DESCRIPTION
02-04-00
Rev. A
05/12/00
94 - 01 (BR)
Squeaking/clicking noise from rear leaf springs.

If the vehicle has a squeaking/clicking noise coming from the rear of the vehicle, verify that
the noise is coming from the rear springs as the vehicles 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
05/01/00
00 (BR)
High pitched squeal from rear brakes.

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
06/09/00
00 - 01 (BR)
Front brake caliper anti-rattle clip retainer service procedures.

This bulletin applies to vehicles built before June 26, 2000. Vehicles built between April 19, 2000,
and June 26, 2000, were built with a front brake caliper anti-rattle clip retainer. This Technical
Service Bulletin provides the installation procedures for the retainer.
CATEGORY 8
ELECTRICAL
TSB#
MODELS
SUBJECT/DESCRIPTION
08-05-00
04/21/00
99 (BR)
Intermittent operation of the instrument cluster.

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
03/17/00
99 - 00 (BR)
Inoperative or intermittent remote keyless entry (RKE) transmitter.

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
03/24/00
94 - 00 (BR)
Recordable compact discs used in automotive CD players.

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
04/28/00
94 - 00 (BR)
Front door speaker buzz.

The bulletin discusses a buss noise coming from the front door speaker(s). The noise may
be more noticeable while listening to talk radio segments with deep male voices. The repair
procedure involves installing a urethane foam pad between the inner door panel and the door
trim.
36
CATEGORY 8
ELECTRICALcontinued
08-17-00
05/12/00
99 - 00 (BR)
Intermittent speaker operation/static.

Intermittent operation/static may occur in any or all speakers. The bulletin applies to vehicles
equipped with the Infinity sound system sales codes (RBR, RBN, and RAZ) built before October
1, 1999. This repair involves installing new speaker kits on both right and left front doors and
installing foam between the inner door trim panel and the door.
08-18-00
05/12/00
98 - 01 (BR)
Radio Interference to/from two-way radio receivers.

Customers may complain of intermittent poor reception on their two-way radios. This bulletin
involves installing a RFI filter in series with the electric fuel pump motor.
08-23-00
06/23/00
98 - 01 (BR)
Plastic boot to protect the electrical harness B+ end terminal at the generator.
While service is being performed to the engine, it may be possible for a momentary electrical
short to occur. The electrical short may be caused when a metallic object, such as a wrench or
oil filter, comes in contact with the B+ end terminal of the generator wire harness. The B+ end
terminal is bolted to the generator B+ stud (output terminal). The B+ stud on the generator is
protected by a plastic surround. Part of the wire harness end terminal may extend beyond the
protective plastic surround for the B+ output terminal.
This bulletin applies to vehicles equipped with a 5.9L 24V diesel engine built before engine
serial number 56681800 with a date of manufacture of January 29, 2000. The repair procedure
involves the installation of a protective rubber boot (part number 04487042) over the B+ terminal.
08-26-00
09/29/00
00 - 01 (BR)
CATEGORY 9
Central timer module electrically locks-up.

This bulletin applies to vehicles equipped with remote keyless entry (sales code GXR). In addition,
this bulletin applies to vehicles built on or before the following build dates: Ram trucks built at
the St. Louis North Assembly Plant on or before August 21, 2000; Ram trucks built at the Saltillo
Truck 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.
ENGINE
TSB#
MODELS
SUBJECT/DESCRIPTION
09-02-00
02/18/00
99 - 00 (BR)
A heavy oil or fuel-like odor coming from the diesel engine compartment.
This bulletin applies to vehicles equipped with a 5.9L diesel engine. The problem is a heavy oil
or fuel-like odor coming from the engine compartment. This condition may occur after the engine
oil has been changed. The odor appears to reduce in intensity as the engine oil ages. This aging
usually occurs between the first 300 to 500 miles following the oil change.
The odor condition is the result of certain diesel engine oil additives. These oil additives are
blended with the base oil during the manufacture of the engine oil. Some diesel engine oils with
the American Petroleum Institute quality rating of CH-4 or CH-4+ may be more prone ot exhibiting
the odor condition.
The DaimlerChrysler recommended diesel engine oil (p/n 04798231 or p/n 0479832) is formulated
to minimize the heavy oil odor condition.
09-03-00
02/18/00
00 (BR)
Engine oil seepage past the oil fill cap on 5.9L-24V diesel engine.
This bulletin applies to vehicles equipped with a 5.9L-24V diesel engine built before engine serial
number 56664950 with a 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.
37
CATEGORY 14
FUEL
TSB#
MODELS
SUBJECT/DESCRIPTION
14-01-00
02/04/00
00 (BR)
Thump/bump sound heard 1-3 seconds after the vehicle comes to a stop.
This bulletin applies to 2500 series Club/Quad cab vehicles equipped with the 6 foot box built
before December 1, 1999.
Customers may hear a thump/bump sound that occurs 1-3 seconds after the vehicle comes to a
complete stop. In some cases, the thump/bump sound may be transmitted through the floor of the
vehicle allowing the customer to feel the thump/bump in the floor pan of the vehicle. The sound
will only occur when the fuel level of the vehicle is between and 7/8 tank of fuel.
Since the fuel level of the vehicle must be between to 7/8 full, the condition may be difficult to
diagnose. The repair involves replacing the fuel tank.
14-02-00
04/14/00
00 - 01 (BR)
Crack in diesel fuel filter housing cover caused by an improper servicing procedure.
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
04/14/00
98 - 01 (BR)
Maintenance to the Water-In-Fuel sensor probes due to possible fuel contamination.

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
Rev. A
12/21/00
98 - 01 (BR)
Driveability enhancements for winter fuel use and for hard starts.
This bulletin applies to vehicles equipped with a 5.9L-24V diesel engine built between engine
serial numbers 56419738 to 56798357, with a date of manufacture of December 16, 1997 to
November 15, 2000.
The customer may complain of poor driveability when winter fuel is used to power the engine. Or,
the customer may complain of a hard or no-start condition, while the engine is at normal operating
temperatures, when using any type of good quality diesel fuel. The poor driveability condition may
occur only when either straight #1 diesel fuel is used or when other special cold climate winter
blend fuels are in use.
The no-start or long engine crank condition may occur when attempting to restart the engine
while the temperature of the engine is till close to its normal operating temperature. This hard
hot restart condition may be experienced in all ambient climates, but may be more of a concern
in warmer ambient climates. The repair involves selectively erasing and reprogramming the
Cummins CM551 Engine Control Module (ECM) with new software.
18-024-00
12/21/00
38
01 (BR)
Low engine power when the automatic transmission is in overdrive.

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.
CATEGORY 18
The customer may complain of low engine power and/or poor performance. This engine condition
may occur while the automatic transmission is being operated in its overdrive gear. This condition
may be further aggravated if the customer is using the vehicle for towing purposes.
The Engine Control Module (ECM) software, on a 2001 Ram Truck equipped with a 24-valve
diesel engine, is designed to torque manage the power output of the engine. This is done to
protect the automatic transmission components. The revised software calibration restores the
power output and improves the vehicle performance in overdrive.
Note: If TSB 18-015-00 Rev A has previously been performed too the vehicle in question, then
the ECM software has already been revised with the correct calibration to address the above
condition. The ECM will not require reprogramming.
The repair procedure involves selectively erasing and reprogramming the Cummins CM551
Engine Control Module (ECM) with new software (calibration versions: 56T13, 59T6). There is no
change to the JTEC PCM software.
CATEGORY 19
STEERING
TSB#
MODELS
SUBJECT/DESCRIPTION
19-04-00
06/09/00
94 - 00 (BR)
Squeaking/creaking sound in steering column while turning.

This bulletin applies to vehicles equipped with non-tilt steering columns. A squeaking/creaking
sound may be heard coming from the 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
03/10/00
99 - 00 (BR)
47RE transmission-delayed upshift or no TCC engagement between 30 and 50 MPH.

This bulletin applies to vehicles equipped with a federal market 5.9L-24V diesel engine and built
between March 2, 1999 and October 1, 1999.
The customer may experience a condition where the transmission may seem to have a delayed
3-4 upshift, while moderately accelerating from 30 to 50 MPH. The customer may also note high
engine rpms 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
06/30/00
96 - 99 (BR)
Erroneous MIL illumination for P1763 Transmission Governor Pressure Sensor Volts Too High.
Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763
Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience
slower than normal vehicle accelerations because the transmission may have temporarily
entered its 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.
This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control
Module (PCN) with new software.
39
CATEGORY 21
21-08-00
09/01/00
99 - 00 (BR)
47RE delayed TCC lock-up and/or MIL P1740 TCC or O/D Solenoid Performance.
This information applies to vehicles build for the California market (NAE), equipped with a
5.9L-24V diesel engine and built between March 2, 1999 and October 1, 1999.
The customer may experience a delayed torque converter clutch engagement (lock-up). This
condition may illuminate the Malfunction Indicator Lamp (MIL) due to Diagnostic Trouble Code
(DTC) P 1740 TCC or O/D Solenoid Performance. In some 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
09/15/00
00 - 01 (BR)
CATEGORY 23
Tapping/knocking sound during idle.

This bulletin applies to vehicles built before May 10, 2000, equipped with an automatic
transmission. A tapping/knocking sound may be heard or felt in the driver side floor pan area
during idle conditions. With the engine running at an idle, listen for knocking sound coming form
the driver side floor pan area. If a tapping/knocking sound can be heard, replace the shift linkage
with revised parts.
BODY
TSB#
MODELS
SUBJECT/DESCRIPTION
23-03-00
02/04/00
00 (BR)
Vehicle Identification Number (VIN) Plate Relocated

The VIN plate on the subject model vehicles has been relocated from the instrument panel to the
cowl bar. Due to the relocation of the VIN plate, the windshield frit (the frit is the black-out band at
the bottom of the windshield) required a change so that the VIN plate could be seen through the
windshield. The view of the VIN plate may be blocked if a 1999 or earlier windshield is installed
on the vehicle.
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
05/05/00
94 - 01 (BR)

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 p0anel 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
06/30/00
97 - 01 (BR)
Paint fogging/whitening.
Painted surfaces of the vehicle that are covered for extended periods of time with front end
covers (bras), transit films or magnetic signs may appear to have a white milky spot on dark
colors, or a fogging, coffee colored spot lighter colors. The repair involves removal of a fogging
or staining condition from any painted surface where moisture may be trapped under the clear
coat by using a heat gun.
40

CATEGORY 2
FRONT SUSPENSION
TSB#
MODELS
SUBJECT/DESCRIPTION
02-001-01
1/19/01
94 - 01
Rear of vehicle sits too high to allow hook up to a fifth-wheel trailer.

This bulletin applies to 2500 and 3500 4x4s. The curb hight lowering package is designed to
reduce the rear spring spacer block by 1 7/8 inch, which will lower the rear of the 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
3/9/01
01
Parking brake pedal adjustment.

This bulletin applies to 2500/3500 series Ram trucks with four-wheel disc brakes, built before
November 20, 2000. Parking brake cable appears to be mis-adjusted, which may cause the
parking brake lamp to remain illuminated even after the parking brake pedal has been released.
The parking brake system, however, is not mis-adjusted and functions normally. Install new
parking brake cables.
CATEGORY 8
ELECTRICAL
TSB#
MODELS
SUBJECT/DESCRIPTION
08-010-01
5/25/01
94 - 02
Airbag/clock spring service.

When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. Do
not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Any repair that may
disrupt the positioning of the steering wheel with the front wheels will require that the clock spring
be centered. This includes clock spring replacement, steering column service, HVAC service,
steering gear service, and front suspension crossmember service.
CATEGORY 9
ENGINE
TSB#
MODELS
SUBJECT/DESCRIPTION
09-002-01
03/02/01
98 - 01 (BR)
Exhaust manifold bolt retention straps.

This bulletin applies to vehicles equipped with a 24-valve diesel engine built on or between
engine serial number 56419738 and 56777585, with a date of engine manufacture from January
01, 1998 to September 22, 2000. This information is available on the engine data plate, which is
located on the left side of the engine, affixed to the side of the timing gear housing.
Vehicles that are used for extended heavy trailer hauling purposes may experience a loss of
exhaust manifold bolt torque. This condition may lead to exhaust gas blow-by past the exhaust
manifold gasket(s) and even loss of exhaust manifold bolts.
A new exhaust manifold bolt retention strap has been released as a means of locking the outboard
exhaust manifold bolts in place. This will prevent bolt rotation and torque loss during the thermal
expansion and contraction cycles of the exhaust manifold.
41
CATEGORY 9
ENGINEcontinued
09-001-01
1/19/01
01
Intermittent loss of oil pressure sensor ouput voltage.

This bulletin applies to 2500/3500 diesels with engine serial number 56744083 to 56809910. The
output voltage of the oil pressure sensor may intermittently dropout. This condition may cause
the engine oil pressure gauge needle to erroneously indicate lower than actual oil pressure. A
warning chime may sound and the Check Gauges lamp may illuminate. The Engine Control
Module (ECM) software has been revised to address this condition. Replacing the oil pressure
sensor will not correct this condition.
09-003-01
5/4/01
All
Engine oil additives/supplements.

Engine oil additives/supplements (EOS) should not be used to enhance engine oil performance.
Engine oil additives/supplements should not be used to extend engine oil change intervals. No
additive is known to be safe for engine durability and can degrade emission components. Additives
can contain undesirable materials that harm the long term durability of engines. Generally it is
not desirable to mix additive packages from different suppliers in the crankcase; there have
been reports of low temperature of low temperature engine failures caused by additive package
incompatibility with such mixtures.
09-006-01
08/24/01
98 - 02 (BR)
Engine oil pan gasket sealing.

This bulletin applies to Ram trucks equipped with the 24-valve diesel engine. Repeat oil pan gasket leaks can occur on 24-valve diesels if the gasket is applied without the use of Mopar Silicon
Rubber Adhesive (RTV) sealant (PN 04883971). This bulletin provides specific routing of the
sealant when replacing the engine oil pan gasket. When replacing an oil pan gasket, apply a 1/8
bead of RTV to the oil pan side of the gasket, around the back of the engine, extending up to the
fourth bolt hole from the rear on each side, as per the referenced diagram.
To be
determined
98 - 02 (BR)
Crankcase breather overflow.

This bulletin applies to 98 - 02 (BR) Ram trucks equipped with the 24-valve Cummins diesel
engine built after March 27, 1998 (ESN 56443872). Owners of 98 - 02 trucks equipped with the
24-valve Cummins diesel engine may experience engine oil overflow from the front crankcase
breather when the vehicle is operated on an extreme downhill grade (36.5% or 22 slope/grade).
Operation of this type for extended periods of time can cause enough engine oil depletion to
damage the engine. A kit containing all components necessary to eliminate the oil overflow has
been made available. The bulletin outlines the repair procedure that relocates the breather from
the front of the engine to a new location on the drivers side tappet cover.
CATEGORY 18
VEHICLE PERFORMANCE
TSB#
MODELS
SUBJECT/DESCRIPTION
18-31-1
New
Release
98.5 - 2002 (BR/BE)
Cold idle engine warming.

This bulletin involves selectively erasing and reprogramming the Engine Control Module with new
software. This bulletin applies to all Ram trucks built after December 17, 1997 equipped with the
24-valve 5.9L Cummins diesel engine.
Extended idle operation, especially in cold weather, can allow varnishes/oils to condense on
the exhaust valve stems, leading to stuck valves, and damaged valve train components. The
repair procedure involves calibration software that will activate when certain parameters are met,
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 60C (32F)
Coolant Temp is less than 60C (140F)
The transmission is in Neutral or Park
The Service Brake pedal is not depressed
Throttle = 0%
Vehicle Speed = 0 mph
42
CATEGORY 18
If intake manifold temperature (IMT) is less than -9C (15F), three of the cylinders will be shut
off upon reaching 1200 rpm, creating a slight change in engine sound which is normal. Thus
the engine has to work to overcome the three dead cylinders. This allows the engine to create
increased heat in the cooling system, allowing more rapid warm up.
Either feature will abort when any one of the following occurs:
The automatic transmission is placed in gear (forward or reverse)
The service brake pedal is depressed
Throttle position is greater than 0%
Vehicle speed greater than 0 mph
Coolant temperature is greater than 79C (175F)
CATEGORY 21
TRANSMISSION
TSB#
MODELS
SUBJECT/DESCRIPTION
21-004-01
02/16/01
01 (BR)
Overdrive disabled to improve transmission reliability during cold temperature operation.

This bulletin applies to vehicles equipped with an automatic transmission where the vehicle was
built on or between June 26, 2000 and December 23, 2000, and the PCM software level is earlier
(lower) than calibration 14 for model year 2001.
Quality analysis has determined that insufficient lubrication of certain internal transmission
components may occur when a vehicle is operated in temperatures lower than -20C (-5F). 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 -20C (-5F) are
experienced.
The revised software will not allow 4th gear overdrive to occur if ambient temperatures are less
than -20C (-5F). The revised PCM software has been implemented to improve transmission
reliability. The customer should be informed that reduced fuel economy would be expected when
overdrive is not in use.
The repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM)
with new software (calibration level 01Cal14).
CATEGORY 25
EMISSIONS
TSB#
MODELS
SUBJECT/DESCRIPTION
25-001-01
1/19/01
01 (BR/BE)
Generic Scan Tool May Not Display Certain DTCs and Erroneous LDP Switch.
This bulletin applies to vehicles with an RE automatic transmission built before January 12, 2001
(MDH 0112XX). A generic scan tool may not display certain Diagnostic Trouble Codes (DTC)
when a Malfunction Indicator Lamp (MIL) illuminates. The PCM software must be updated to
calibration level 0lCall4A.
25-002-01
1/19/01
01 (BR/BE)
Scan Tool Erroneously Displays P000 For DTCs P1740 And P0461.
This bulletin applies to vehicles with an RE automatic transmission built before January 31,
2001 (MDH 0131XX). A Generic Scan Tool or an Enhanced Scan Tool, like the DRB III, may
erroneously display certain Diagnostic Trouble Codes (DTC) as P0000. As a result, the scan tool
may display Freeze Frame data incorrectly. The PCM software must be updated to calibration
level 0lCall4A.
43

CATEGORY 2
FRONT SUSPENSION
TSB#
MODELS
SUBJECT/DESCRIPTION
02-001-01
1/19/01
94 - 01
Rear of vehicle sits too high to allow hook up to a fifth-wheel trailer.

This bulletin applies to 2500 and 3500 4x4s. The curb height lowering package is designed to
reduce the rear spring spacer block by 1 7/8 inch, which will lower the rear of the vehicle by
several inches providing clearance so that most customers can attach their fifth-wheel or goose
neck trailer to the trailer hitch turntable.
CATEGORY 5
BRAKES
TSB#
MODELS
SUBJECT/DESCRIPTION
05-002-01
3/9/01
01
Parking brake pedal adjustment.

This bulletin applies to 2500/3500 series Ram trucks with four-wheel disc brakes, built before
November 20, 2000. Parking brake cable appears to be mis-adjusted, which may cause the
parking brake lamp to remain illuminated even after the parking brake pedal has been released.
The parking brake system, however, is not mis-adjusted and functions normally. Install new
parking brake cables.
CATEGORY 8
ELECTRICAL
TSB#
MODELS
SUBJECT/DESCRIPTION
08-010-01
5/25/01
94 - 02
Airbag/clock spring service.

When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. Do
not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Any repair that may
disrupt the positioning of the steering wheel with the front wheels will require that the clock spring
be centered. This includes clock spring replacement, steering column service, HVAC service,
steering gear service, and front suspension crossmember service.
08-016-01
8/3/01
02 (BR/BE)
Locking radio antenna connector.

This information only bulletin applies to all 2002 vehicles equipped with radios. The radio units will
have a new locking radio antenna connector. This connector requires that a sliding plastic collar
be pulled away from the radio, similar to an air hose connector, to release the lock. Pulling the
antenna out of the radio without activating the release could damage the antenna or the radio.
08-017-01
9/21/01
02 (BR/BE)
Safety systems -- Vehicle modifications/repair.

Any of the safety systems may be disabled by inadvertent damage to wiring or system components
or by changing or modifying the location of a component.
08-025-01
11/23/01
94 - 01 (BR/BE)
Airbag on-off switches.

This bulletin supersedes technical service bulletin 08-037-99, dated 11/12/99. This bulletin is
provided to identify the parts and procedures necessary to deactivate airbags authorized by
NHTSA. Airbag deactivation is a customer pay procedure, not covered under the provisions of
the warranty. The component parts are covered under the appropriate Mopar part warranty.
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. The switches are packaged in a kit containing all necessary parts (except as indicated)
and a detailed instruction sheet. Under the National Highway Traffic Safety Administrations
rule, consumers will be authorized for on-off switches by claiming they meet any of several
criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the
NHTSA authorization letter. For more information concerning the authorization process and/
or the authorization letter call NHTSAs Auto Safety Hotline at 1-800-424-9393. We encourage
the dealer to install these switches when the customer is interested in doing so and has the
necessary NHTSA authorization.
44
CATEGORY 9
ENGINEcontinued
TSB#
MODELS
SUBJECT/DESCRIPTION
09-002-01
03/02/01
98 - 01 (BR)
Exhaust manifold bolt retention straps.

This bulletin applies to vehicles equipped with a 24-valve diesel engine built on or between
engine serial number 56419738 and 56777585, with a date of engine manufacture from January
01, 1998 to September 22, 2000. This information is available on the engine data plate, which is
located on the left side of the engine, affixed to the side of the timing gear housing.
09-001-01
1/19/01
01
Intermittent loss of oil pressure sensor ouput voltage.

This bulletin applies to 2500/3500 diesels with engine serial number 56744083 to 56809910. The
output voltage of the oil pressure sensor may intermittently dropout. This condition may cause
the engine oil pressure gauge needle to erroneously indicate lower than actual oil pressure. A
warning chime may sound and the Check Gauges lamp may illuminate. The Engine Control
Module (ECM) software has been revised to address this condition. Replacing the oil pressure
sensor will not correct this condition.
09-003-01
5/4/01
All
Engine oil additives/supplements.

Engine oil additives/supplements (EOS) should not be used to enhance engine oil performance.
Engine oil additives/supplements should not be used to extend engine oil change intervals. No
additive is known to be safe for engine durability and they can degrade emission components.
Additives can contain undesirable materials that harm the long term durability of engines. Generally
it is not desirable to mix additive packages from different suppliers in the crankcase; there have
been reports of low temperature engine failures caused by additive package incompatibility with
such mixtures.
09-004-01
5/18/01
89 - 93 (AD)
94 - 01 (BR/BE)
Engine lubricant.
This bulletin involves 1989 2001 Ram trucks equipped with the 5.9L Cummins diesel engines.
This bulletin discusses the recommended oil filters for use with Cummins 5.9L diesel engine:

Part No.
Manufacturer

05016547AC Mopar
LF3894 Fleetguard Stratapore
LF3552 Fleetguard Microglass
LF3959 Fleetguard Cellulose
3937695 Cummins Cellulose
FL896 MotorCraft Cellulose
L45335 Purolator Cellulose

PF1070
AC Delco Cellulose
The information only bulletin was issued to alert the field to problems caused by aftermarket
oil filters. For example, neoprene compounds used internally in the manufacture of oil filters
not recommended by DaimlerChrysler may separate from the filter, lodge in the piston cooling
nozzle, and cause the engine to fail. This is not an engine defect.
09-006-01
08/24/01
98 - 02 (BR)
Engine Oil Pan Gasket Sealing

This bulletin applies to Ram trucks equipped with the 24-valve diesel engine. Repeated oil pan
gasket leaks can occur on 24-valve diesels if the gasket is applied without the use of Mopar
Silicon Rubber Adhesive (RTV) sealant (PN 04883971). This bulletin provides specific routing of
the sealant when replacing the engine oil pan gasket. When replacing an oil pan gasket, apply a
1/8 bead of RTV to the oil pan side of the gasket, around the back of the engine, extending up to
the fourth bolt hole from the rear on each side, as per the referenced diagram.
09-002-02
3/11/02
98 - 02 (BR)
Crankcase Breather Overflow

This bulletin applies to 98 - 02 (BR) Ram trucks equipped with the 24-valve Cummins diesel
engine built after March 27, 1998 (ESN 56443872). Owners of 98 - 02 trucks equipped with the
24-valve Cummins diesel engine may experience engine oil overflow from the front crankcase
breather when the vehicle is operated on an extreme downhill grade (36.5% or 22 slope/grade).
Operation of this type for extended periods of time can cause enough engine oil depletion to
damage the engine. A kit containing all components necessary to eliminate the oil overflow has
been made available. The bulletin outlines the repair procedure that relocates the breather from
the front of the engine to a new location on the drivers side tappet cover.
45
CATEGORY 18
VEHICLE PERFORMANCE
TSB#
MODELS
SUBJECT/DESCRIPTION
18-019-01
9/3/01
98.5 - 02 (BR/BE)
Cold idle engine warming.

This bulletin addresses selectively erasing and reprogramming the Engine Control Module with
new software. This bulletin applies to all Ram trucks built after 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 is less than 60C (32F)
Coolant Temp is less than 60C (140F)
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 -9C (15F), three of the cylinders will be shut
off upon reaching 1200 rpm, creating a slight change in engine sound which is normal. Thus
the engine has to work to overcome the three dead cylinders. This allows the engine to create
increased heat in the cooling system, allowing more rapid warm up.
Either feature will abort when any one of the following occurs:
The automatic transmission is placed in gear (forward or reverse)
The service brake pedal is depressed
Throttle position is greater than 0%
Vehicle speed is greater than 0 mph
Coolant temperature is greater than 79C (175F)
18-014-01
7/9/01
98 - 02 (BR/BE)
Performance enhancement for severe cold weather environments.

This bulletin applies to all Ram trucks equipped with a 5.9L 24-valve Cummins diesel engine
with a 49-state emissions calibration and an automatic transmission. The bulletin describes how
to selectively erase and reprogram the Powertrain Control Module (PCM) with new software
(59t7a). The problem addressed by the PCM reprogram is a hard starting and/or idle speed
fluctuations condition.
Cummins 24-valve engines used with automatic transmissions can be severely affected by the
use of sub-grade #1 diesel fuel when ambient temperatures are below 0C (32F), typically
prevalent during the Winter months in Alaska, Northwestern Canada, and similar climates/
temperatures elsewhere.
This change will have no effect on performance during warm weather or when standard grade
diesel fuels #1 or #2 are used.
Vehicles with 49-state certification can apply this calibration change if needed. The calibration
can be changed back to the original calibration if desired.
46
CATEGORY 19
STEERING
TSB#
MODELS
SUBJECT/DESCRIPTION
19-009-01
10/26/01
97 - 02 (BE/BR)
Driver airbag trim cover service.

Driver airbag trim covers/horn switches for the above vehicles are serviceable and as such,
when applicable, must be used instead of replacing the airbag module assembly. Airbag module
assemblies returned for trim cover and serviceable horn switch issues, are subject to charge
back.
The horn switch is integral to the driver airbag unit. Only DaimlerChrysler-trained and authorized
dealer service technicians should perform service of this unit. Failure to take the proper
precautions or to follow the proper procedures could result in accidental, incomplete, or improper
airbag deployment and possible occupant injuries.
CATEGORY 21
TRANSMISSION
TSB#
MODELS
SUBJECT/DESCRIPTION
21-004-01
02/16/01
01 (BR)
Overdrive disabled to improve transmission reliability during cold temperature operation.

This bulletin applies to vehicles equipped with an automatic transmission where the vehicle was
built on or between June 26, 2000, and December 23, 2000, and the PCM software level is earlier
(lower) than calibration 14 for model year 2001.
Quality analysis has determined that insufficient lubrication of certain internal transmission
components may occur when a vehicle is operated in temperatures lower than -20C (-5F). 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 -20C (-5F) are
experienced.
The revised software will not allow 4th gear overdrive to occur if ambient temperatures are less
than -20C (-5F). 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).
21-009-01
10/15/01
01 (BE/BR)
NV5600 Countershaft service.

This bulletin involves Ram trucks manufactured prior to March 17, 2001, and equipped with
the NV5600 6-speed, heavy duty transmission. Customers may experience a shifter vibration
(commonly referred to as gear clash) of the shift knob when shifting from one gear to another
between 2500 and 3500 RPM after a cold start up. This condition is most evident when ambient
temperatures are at or near 0C (32F) but can occur at warmer temperatures as well. The
condition is most often reported on 3rd to 4th gear shifting, but can occur in the other shift ranges
as well. The problem can be verified by assuring the transmission is at ambient temperature,
vehicle moving and, with the engine at 2500 to 3500 RPM, shifting into and out of the gear ranges.
This repair may include disassembly of the countershaft assembly, requiring the use of a 20-ton
press. Attempts to use lesser equipment to effect this repair could result in damage or injury.
If such a press is available, rebuilding the countershaft assembly is preferred. In the event a press
is not available, a new countershaft assembly (PN 05073361AA) has been made available.
Follow the service procedures in the appropriate service manual to complete necessary repairs.
Follow normal warranty procedures to report the repairs.
Automatic transmission fluid usage ATF+4 (Type 9602).
47
CATEGORY 21
21-006-01
6/29/01
94 - 02 (BR/BE)
This information only bulletin supersedes technical service bulletin 21-16-99, dated October 22,
1999. The bulletin discusses a new transmission fluid (ATF+4 Type 9602) which has been
developed and is being used as factory fill for all vehicles with Chrysler automatic transmissions.
Until now, vehicles originally filled with ATF+2 or ATF+3 were to be serviced with ATF+3. Effective
immediately, it is recommended that all vehicles with Chrysler automatic transmissions except for
1999 and earlier minivans be serviced with ATF+4. ATF+3 should continue to be used for 1999
and earlier minivans because of the potential for torque converter shudder during break in. For all
other applications the ATF+4 fluid offers significant benefits as outlined below.
ATF+4 must always be used in vehicles that were originally filled with ATF+4.
Service intervals do not change. The service interval currently in effect for a given vehicle should
continue to be followed.
ATF+4 is compatible with ATF+3 and can be used to top off vehicles that currently have ATF+2 or
ATF+3. Do not use ATF+2 or ATF+3 to top off vehicles that have ATF+4 fluid.
Benefits:
Better anti-wear properties
Improved rust/corrosion prevention
Controls oxidation
Eliminates deposits
Controls friction
Retains anti-foaming properties
Superior properties for low temperature operation
Mopar ATF+4 is a World Class Fluid having exceptional durability. However, the red dye used in
ATF+4 is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4
also has a unique odor that may change with age. With ATF+4 fluid, color and odor are no longer
indicators of fluid condition and do not support a fluid change.
CATEGORY 22
WHEELS
TSB#
MODELS
SUBJECT/DESCRIPTION
22-001-01
Rev. A
9/28/01
00 - 01 (BR/BE)
Chrome wheel care.

Chrome wheels should be cleaned regularly with mild soap and water to maintain their luster and
prevent corrosion. Wash them with the same soap solution as the body of the vehicle.
To clean extremely dirty wheels care must be taken in the selection of tire and wheel cleaning
chemicals and equipment to prevent damage to wheels. Only Mopar Wheel Treatment, p/n
05066247AB 12 oz. Or 05066248AB 5 gal., is recommended to remove brake dust, dirt,
grease and grime. Any of the DO NOT USE items listed below can damage or stain wheels and
wheel trim.
DO NOT USE:
Any abrasive type cleaner
Any abrasive cleaning pad (such as steel wool) or abrasive brush
Any cleaner that contains an acid (this will immediately react with and discolor the
chromium surface)
Any oven cleaner
Any abrasive metal cleaner.
Chrome polish unless it is buffed off immediately after application.
Any abrasive cleaning pad or brush
A car wash that has carbide tipped wheel-cleaning brushes.
48
CATEGORY 23
BODY
TSB#
MODELS
SUBJECT/DESCRIPTION
23-027-01
9/21/01
98 - 02 (BR/BE)
Equipped with
6x9 Mirrors
Sales Code GPS
or GPU
Outside rearview mirror glass replacement.

This bulletin supersedes technical service bulletin 23-034-00 Rev. A, dated December 15, 2000.
It is unnecessary to replace the entire outside rearview mirror assembly when the mirror glass
is broken or is missing. Replacement mirror glasses are available from Mopar. Because of the
extremely long list of part numbers involved, please consult the Mopar parts catalog for the
correct part number(s).
23-034-01
11/30/01
00 - 01 (BR/BE)
Scratching sound from the door seal while driving.

A scratching or itching type sound may be heard, coming from the front door opening. If a
customer indicates that the condition is present, perform the repair procedure, which involves
lubricating the secondary door seal with part number 04773427: Weather Seal Lubricant.
CATEGORY 25
EMISSIONS
TSB#
MODELS
SUBJECT/DESCRIPTION
25-001-01
1/19/01
01 (BR/BE)
Generic Scan Tool May Not Display Certain DTCs and Erroneous LDP Switch.
This bulletin applies to vehicles with an RE automatic transmission built before January 12, 2001
(MDH 0112XX). A generic scan tool may not display certain Diagnostic Trouble Codes (DTC)
when a Malfunction Indicator Lamp (MIL) illuminates. The PCM software must be updated to
calibration level 0lCall4A.
25-002-01
1/19/01
01 (BR/BE)
Scan Tool Erroneously Displays P000 For DTCs P1740 And P0461.
This bulletin applies to vehicles with an RE automatic transmission built before January 31,
2001 (MDH 0131XX). A Generic Scan Tool or an Enhanced Scan Tool, like the DRB III, may
erroneously display certain Diagnostic Trouble Codes (DTC) as P0000. As a result, the scan tool
may display Freeze Frame data incorrectly. The PCM software must be updated to calibration
level 0lCall4A.
49
TSBs Issued 2003-2009

CATEGORY 2
FRONT SUSPENSION
TSB#
MODELS
SUBJECT/DESCRIPTION
02-003-02
6/17/02
00 - 02 (BR/BE)
Toe-in specification change.

This bulletin involves an update to the toe-in specification for front end alignments. The
specification for toe-in has been revised to 0.2 0.1 total toe in. This change has been shown to
improve straight ahead driving performance and should be used whenever a front end alignment
is performed.
02-003-08
6/20/08
08 (DM)
4500/5500
Front and/or rear shock absorber noise.

The customer may experience a clunking-like sound when traveling over small inputs (bumps
and dips) in the road. This clunk-like sound is sometimes described as being similar to the
sound that loose lumber may make when loose boards strike each other. This condition is
more noticeable during cold ambient conditions below 40F and at lower vehicle speeds when
background noise is less. The sound may come from the front and/or rear shock absorbers.
This condition is due to internal components within the vehicle shock absorber and the bulletin
describes the replacement procedure.
CATEGORY 3
AXLE/DRIVELINE
TSB#
MODELS
SUBJECT/DESCRIPTION
03-001-02
2/11/02
02 (BR/BE)
Front axle disconnect system.

This bulletin involves a mid-2002 model year deletion of the front axle disconnect system on
2002 (BE/BR) 2500 and 3500 Ram Trucks. This change effects the front axle, transfer case
and engine/headlamp and dash wiring harnesses. The bulletin applies to 2500 and 3500 (BE/
BR) Ram trucks built after January 4, 2002 and equipped with front axles with the following part
numbers: 52070136AO, 52070137AO, 52070138AP, and 52070139AO.
The vehicles involved will retain Shift On the Fly (SFO) capability; however, with this change, the
front driveshaft will now turn continuously when the vehicle is being driven. Due to the timing of
this change this information is not reflected in the Service Manual and a future release will outline
service procedures.
03-002-02
7/1/02
02 - 03 (DR)
Use of synthetic rear axle lubricant.

This bulletin applies to 2002-2003 (DR) Ram trucks equipped with the 9 rear axle and trailer
tow package. It is critical to optimum performance in trailer towing conditions that when service is
being performed on the 9 rear axle on 2002-2003 (DR) Ram trucks, the axle must be refilled
with Mopar 75W-140 synthetic gear and axle lubricant (PN 04874469). Five ounces (148ml) of
Mopar friction modifier (PN 04318060AB) must also be added to vehicles equipped with the traclok style rear axle.
03-003-04
6/15/04
03 - 04 (DR)
Launch shudder.
This bulletin involves adjusting the propeller shaft working angles and applies to vehicles
equipped with a two-piece rear driveshaft. The problem is described as a drive line shudder or
vibration while accelerating from a stop. The condition is most noticeable under heavy throttle
acceleration and is usually present only at low speeds (below 25 mph). Vehicles equipped with
a two-piece driveshaft are designed to minimize reaction forces that result from the universal
joint transmitting torque at an angle. These forces cannot be eliminated entirely because of
the necessity to compromise joint angle selection between curb and design loading conditions.
U-joint angles change depending upon the amount of weight applied to the vehicle bed.
50
CATEGORY 3
AXLE/DRIVELINEcontinued
Therefore U-joint angle readings may need to be taken with different vehicle loads in order to
obtain a satisfactory compromise. The vehicle should be evaluated under the loaded condition
that produces the objectionable disturbance.
The repair procedure involves measurements at the transmission yoke, front propeller shaft,
rear propeller shaft and rear axle. The working angles should be adjusted to provide the lowest
angle possible for the output shaft to front propeller shaft, front propeller shaft to rear propeller
shaft, and rear propeller shaft to axle pinion. The measurements will determine which direction
to move the center bearing to optimize the angles. Install the appropriate bracket to obtain the
minimum working angle, but still maintain at least degree to ensure that there will be some
movement in the U-joint bearings.
03-004-04
6/22/04
03 - 04 (DR)
Axle whine.
This bulletin applies to 4x2, 2500 series, 140.5 inch wheelbase vehicles equipped with diesel
engine, sales code ETC/ETH, and an automatic transmission, sales code DG8. The problem is
that some vehicles may exhibit rear axle whine at speeds between 35 and 70 mph. The repair
procedure involves identification of the pinion flange and propeller shaft that the vehicle is
equipped with. If a repair is necessary, the propeller shaft is replaced using the chart listing the
appropriate part numbers.
03-003-06
10/20/06
03-07 (DR)
Axle-fluid level.
This bulletin supersedes TSB 03-001-04, revision A dated 5/11/04.
The axle fill holes on some 2004 Dodge Truck axles may be located considerably higher than
the actual fluid level. Filling the axle until the fluid comes out of the fill hole will overfill the axle,
which could cause fluid foaming. When checking fluid level or filling a rear axle with fluid, you
must measure distance from the bottom of the fill hole to the actual fluid level. This can easily
be accomplished using a pipe cleaner or piece of wire. Make a 90 degree bend in the wire two
inches from the end. The wire can then be inserted into the axle fill hole and used as a dipstick.
Measure the distance from the bend to the oil level. The fluid levels for the axles are shown in
the table below.
Ram Truck 2500/3500

Axle
10.5 Rear Axle
11.5 Rear Axle
9- Front Axle
Fluid Level (measured from the bottom of the fill hole)

1 inch inch
inch inch
inch inch
Fluid Capacity
85 oz. SAE 75W-90 Synthetic
Note: The limited slip feature on 2500/3500 series Ram Trucks utilizes the Trac Rite locking
feature which does not require Trac-Lok additives or friction modifiers.
CATEGORY 6
CLUTCH
TSB#
MODELS
SUBJECT/DESCRIPTION
06-001-03
5/16/03
03 (BR)
Rattle sound from transmission when idling.

This bulletin applies to vehicles equipped with a 5.9L Cummins high output Turbo Diesel (sales
code ETH) and NV5600 six-speed manual transmission (sales code DEE) built on or before May
11, 2003. The vehicle operator may describe a rattle sound when idling in neutral with the clutch
pedal released. The bulletin involves replacing the clutch disc with a revised part.
06-001-07
2/03/07
07
Clutch system may over-adjust causing difficulty engaging transmission gear.

This bulletin involves replacement of the clutch system flywheel, pressure plate, and disc.
This bulletin applies to vehicles equipped with a 5.9 liter or 6.7 liter Cummins Turbo Diesel engine
and the G56 manual transmission (sales code ETH, ETJ, and DEG respectively), and built on or
before November 09, 2006.
51
CATEGORY 6
CLUTCHcontinued
The customer may experience difficulty attempting to engage a manual transmission gear. This
may be due to the self-adjusting mechanism in the clutch system. The self-adjusting clutch
mechanism may over-adjust (forward adjust). This condition most often will occur within the first
1,000 miles of vehicle operation.
The bulletin describes the proper repair technique to replace the flywheel, clutch plate, and clutch
disc.
CATEGORY 8
ELECTRICAL
TSB#
MODELS
SUBJECT/DESCRIPTION
08-016-02
9/2/02
02 - 03 (DR)
Horn chirp and erroneous alarm.

This bulletin involves reprogramming the forward control module (FCM) should there be an erroneous horn chirp when a door is opened or an erroneous alarm. The correction is a reflash of
the FCM.
08-004-03
3/14/03
02 - 03 (DR)
Electro mechanical instrument cluster (MIC) erroneous indicator lamps.

Three conditions have been identified which may be caused by communication errors between
the electro mechanical instrument cluster (MIC) and other electronic modules on the vehicle.
1. An intermittent false Check Gauges on diesel engine equipped vehicles. 2. An intermittent
false chime and Low Wash indicator. 3. A Trans Temp indicator on a manual transmissions
equipped vehicle.
This bulletin involves selectively erasing and reprogramming the MIC with new software.
08/007/03
4/4/03
03 (DR)
Alternator mounting bracket cracked.

This bulletin applies to vehicles equipped with a 5.9L 24-valve diesel engine (sales codes ETC,
or ETH) and built on or before February 13, 2003, with engine serial numbers prior to 57013271.
The problem is that the vehicle operator may experience an accessory drive belt squeal during
normal driving conditions. This bulletin describes how to replace the alternator support bracket
with a revised bracket.
08-019-03
6/20/03
03 (DR)
Lamp-out indicator with aftermarket pickup box installation.

This information-only bulletin discusses situations where an aftermarket utility box is installed
after the removal of the original equipment pickup box. Under the circumstances the lamp-out
indicator may illuminate. This is due to the use of aftermarket rear stop and turn signal lamps
which use a dual filament bulb instead of separate circuits for the stop and turn indicator. The
bulletin then describes the reprogramming procedure to reset the lamp-out indicator.
08-031-03
10/31/03
03 (DR)
PCM connector corrodedsets MIL light.

This bulletin applies to vehicles equipped with a 5.9 liter diesel engine and an automatic transmission.
Water may enter the PCM connector causing corrosion of electrical terminals on the PCM. This
condition can set diagnostic trouble codes and illuminate the MIL light. If diagnostic trouble codes
are present or other diagnostics lead to PCM connector problems, inspect the PCM and the PCM
wire harness connector. The repair procedure involves replacement of the wiring harness.
08-011-04
3/16/04
04 (DR)
Poor radio sound quality with Infinity speakers.

This bulletin applies to vehicles equipped with Infinity speakers, sales code RCK. Radios
equipped with Infinity Speakers may exhibit a variety of symptoms due to reversed right front
speaker wiring (polarity). Symptoms include: front door or speaker buzz, poor sound quality, lack
of bass. The solution involves correcting speaker wiring polarity in the radio connector.
52
CATEGORY 8
ELECTRICALcontinued
08-014-04
3/30/04
04 (DR)
Radio intermittent audio.

This bulletin applies to vehicles equipped with an AM/FM/cassette radio built prior to January 30,
2004 or AM/FM/CD radio built prior to January 30, 2004. Radios built after 1/30/04 will no longer
have vent holes in the area the repair procedure covers. If the audio drops out when the vehicle
is moved from a cold to a warm or humid environment, the reason is that condensation builds
up across the audio amplifier circuitry, causing the amplifier to shut down. Typically, cycling the
ignition switch off and on will restore the audio output. If the problem persists, the correct repair
procedure is to apply tape over the row of slots on the left hand side of the radios top cover.
08-014-05
2/17/05
04 - 05 (DR)
Mopar accessory remote starter inoperative due to hood switch.

This bulletin applies to vehicles equipped with a Mopar remote starter kit. The problem frequently
occurs as one or more of the following:
When the transmitter is pressed twice for start, the vehicle horn will chirp once but the vehicle
engine will not start.
When the transmitter is pressed twice for start, the vehicle horn will chirp twice, indicating a
problem with the remote start system and the vehicle engine will not start.
When the transmitter is pressed twice for start, the vehicle will chirp once, the engine will
start and then turn off.
The technician may not be able to verify the symptom(s) because it may be an intermittent
condition. The corrective action involves replacing the hood switch for the remote starting system.
08-024-05
5/4/05
02 - 06 (DR)
Radio communication equipment installation recommendations.

This information only bulletin gives the dealership technician some guidelines for the installation
of two-way radio equipment.
08-058-05
10/29/05
05 - 06 (DR)
Revised radio antenna mast installation procedure.

This information only bulletin advises the proper tightening torque (30-32 in-lbs) for the radio
antenna mast for various Chrysler group products.
08-014-06
3/16/06
06 (DR)
UConnect Hands Free module fails to respond due to module lock-up.

This bulletin supersedes service bulletin 08-049-05 dated September 1, 2005, and applies to
vehicles equipped with UConnect Hands Free Communications (sales code RSP) that were built
prior to October 2, 2005. If the UConnect Hands Free Communications system does not respond
when system activation is attempted by the customer, the technical service bulletin gives the
technician the proper repair technique to reset the hands-free module.
08-016-06
Rev. A
7/18/06
06 - 07 (DR)
Intermittent operation of electrical components due to ignition off draw (IOD) fuse not being
fully seated.
This bulletin supersedes technical service bulletin 08-016-06, dated March 22, 2006. The ignition
off draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of
vehicles. If the fuse is not completely inserted, partial contact of the fuse terminals could occur.
When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged. When
the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome
the pre-hold position. On 06 and 07 DR vehicles the circuits fed by the IOD fuse are: Radio,
EVIC, Wireless Control Module, Hands Free Module, Satellite Radio, Video Screen, CCN wakeup with ignition off, Underhood Lamp, and CCN Interior Lighting.
53
CATEGORY 8
ELECTRICALcontinued
08-020-06
5/5/06
06 (DR)
Overhead console average fuel economy display.

This information-only bulletin discusses the calculation method used by the trucks average fuel
economy display. On 06 vehicles, the calculation has been changed to use the last displayed
average fuel economy as a starting point for the calculation after a reset. The average fuel
economy will then be adjusted from that point. If the display read 21.6 mpg at the time the reset
was activated, the new display will start at 21.6 mpg and would change from that point depending
on the current fuel usage. This was done to eliminate the extreme variations caused by very high
or low fuel usage at the time of the reset.
08-021-06
Rev. A
10/13/06
06
TIPM Flash: DTCs indicating short circuits in the wiring on the trailer or no engine crank with DTC
P1277 starter control circuit too low.
This bulletin supersedes technical service bulletin 08-021-06, dated May 10, 2006.
This bulletin involves a discussion and reprogramming of the totally integrated power module
(TIPM). This bulletin applies to vehicles built prior to April 03, 2006.
The customer may experience any of the following TIPM diagnostic trouble codes (DTCs):
B166B - Left Trailer Tow Lamp Control Circuit Low. Trailer harness left lamp circuit is shorted to
ground.
B166C - Left Trailer Tow Lamp Control Circuit High. Trailer harness left lamp circuit is shorted to
battery voltage.
B178C - Left Trailer Tow Lamp Control Circuit Over Current. Trailer harness left lamp circuit is
intermittently grounding.
B166F - Right Trailer Tow Lamp Control Circuit Low. Trailer harness right lamp circuit is shorted
to ground.
B1670 - Right Trailer Tow Lamp Control Circuit High. Trailer harness right lamp circuit is shorted
to battery voltage.
B166E - Right Trailer Tow Lamp Control Circuit Over Current. Trailer harness right lamp circuit is
intermittently grounding.
B1667 - Back Up Lamp Feed Low. Trailer harness back up circuit is shorted to ground.
B2215 - Front Control Module Internal (TIPM). An internal fault code counter has exceeded its
limit of 250 counts and one or more electrical outputs controlled by the TOPM have been
disabled.
P1277 - Starter Control Circuit 2 Low (TIPM). The output feed current to the starter solenoid has
exceeded the upper current limit of 75 amps. This may result in a no-crank condition.
DTCs B1667, B166B, B166E, B166F, B178C and B2215: These DTCs indicate that a (hard
or intermittent) short circuit to ground exists in the wiring of one or more of the trailer electrical
harness circuits. The TIPM retries the output on each ignition cycle or request (brake or turn
signal activation) in an attempt to enable the output in case the fault is intermittent. The new TIPM
software raises the TIPM circuit trigger point from 15 amps to 20 amps.
DTCs B166C and B1670: These DTCs indicate that a short circuit to battery voltage (12 volts)
exists in the wiring of one of the trailer electrical harness circuits.
DTC B2215 - Front Control Module (TIPM): This fault code occurs when the TIPM detects a
short (to ground or to battery) on one of the trailer circuits more than 250 times. When B2215 is
present with one of the above trailer circuit faults, the TIPM will turn off (disable) the respective
faulty trailer circuit or circuits. This internal fault does not mean that the TIPM module is defective.
The TIPM memory can be cleared, and this action will turn on a previously disabled trailer circuit.
If possible, the fault in the circuit should be repaired first before clearing the TIPM memory. The
dealer will need a scan tool to clear the TIPM memory.
DTC P1277 - Starter Control Circuit too Low (TIPM): The TIPM monitors the output current to
the starter solenoid for over-current conditions. The DTC is set when the output current to starter
solenoid exceeds 75 amps. On trucks equipped with a diesel engine, there may be times in cold
climates when it is normal for the starter solenoid current to exceed 75 amps. The new TIPM
software raises the TIPM current trigger point for DTC P1277 from 75 amps to 100 amps.
If any of the DTCs listed above are present, perform the repair procedure.
54
CATEGORY 8
ELECTRICALcontinued
08-026-06
Rev. A
10/25/06
06 (DR/DH/D1)
Overhead console temperature reading inaccurate or dome lamp turns off too soon.
This bulletin supersedes technical service bulletin 08-026-06, dated June 02, 2006.
This bulletin involves selectively erasing and reprogramming the cabin compartment node (CCN)
with new software. This bulletin applies to vehicles built on or before May 30, 2006. The vehicle
owner may notice that if a vehicle door is left open for longer than 20 seconds the illuminated
interior (dome) lamps will turn off. Or the vehicle operator may report that the ambient temperature
first displayed in the overhead console is not accurate (displays -40C or -40F), when the ignition
switch is turned to the On position, then slowly updates to the outside ambient temperature as
the vehicle is driven. If the vehicle operator describes or experiences the symptom/condition,
perform the repair procedure which involves a reflash to the CCN.
08-044-06
10/07/06
07 (DR)
Steering angle sensor over travel performance (DTC:C1240).

This bulletin involves the diagnosis and possible replacement of the steering angle sensor. This
bulletin applies to vehicles equipped with the Electronic Stability Program (sales code BNB) and
built prior to October 03, 2006. The customer may experience an illumination on the instrument
cluster of the ABS (anti-Lock Brake System) and/or the ESP/BAS (Electronic Stability Program/
Brake Assist System) warning lights. Investigation may reveal the presence of diagnostic trouble
code (DTC) C1240 Steering Angle Sensor Over Travel Performance.
If the diagnostic test procedure for DTC C1240 determines that the steering angle sensor is at
fault, then perform the repair procedure.
08-046-06
10/25/06
04-07
Cell phone induced buzz or clicking-like sound in radio speakers.

This bulletin involves a discussion regarding cell phone generated signal interference with the
vehicle radio system. A customer may experience a buzzing or clicking-like sound coming from
the vehicle radio speaker(s). The sound may be heard when the radio is in AM or FM mode. The
clicking-like sound may sound like Morse code.
This information-only bulletin points out that the construction of certain cell phones may generate
frequencies that can interfere with the vehicle radio system. These frequencies may result in
buzzing and/or clicking-like sounds in the vehicle radio. This condition can be easily corrected by
instructing the customer to move their cell phone away from the immediate area around vehicle
radio system (radio, radio amplifier, antenna, antenna lead). Do not replace any radio system
component in an attempt to address this condition.
08-003-07
01/27/07
07 (DR/DH/D1/DC)
Remote start system Diagnostic chart for antenna.

This bulletin involves a diagnostic chart that may be used to aid the technician with the diagnosis of
the antenna on an originally equipped (factory installed) remote start system. This bulletin applies
to vehicles with an original equipment remote start system (sales code XBM). The customer
may notice that the signal range of the remote keyless entry system is reduced (less than 100
feet). This condition may be due to the RKE antenna. The diagnostic flow chart is provided as a
diagnostic aid for dealer technicians.
08-015-07
06/06/07
06-07 (DR)
Flash: Sunroof module, excessive ignition off draw, pop in radio with ignition off, dome lamp
flickers and may not go off.
This bulletin involves selectively erasing and reprogramming the Sunroof Motor Module with new
software.
08-018-07
06/23/07
07 (DR/DH/D1/DC)
MOPAR remote start system RKE intermittent operation or alarm may sound.
This bulletin involves the installation of a Mopar remote start system service repair kit.
55
CATEGORY 8
ELECTRICALcontinued
08-007-08
REV. A
7/4/08
07-08
Engine does not crank or start due to electronic lockup of the remote key module.
This bulletin applies to vehicles built on or before May 05, 2008. The customer may experience
a no engine crank and a no engine start condition. Also, the remote keyless entry system will
not operate. This condition may be due to an electrostatic discharge from the ignition key into
the wireless control module (WCM), causing the WCM to electronically lock up. This condition is
corrected by the replacement of the WCM (also known as the Sentry Key Remote Entry Module).
08-028-08
9/18/08
08 (DR/DH/DC/D1)
Voice recognition screen lock-up on REN or REZ radio equipped with hands-free
communications.
The customer may experience one of the following conditions: a) A lock up condition of the radio
screen when the voice recognition (VR) button is pressed b) When the VR button is pressed, the
radio display changes to the phone screen and there is a lack of the Ready audio prompt.
If the above symptom/condition is experienced, the HFM is replaced. This bulletin applies to
radios built before 11/6/07.
08-035-08
11/21/08
07-09 (DH/D1)
Proper testing tools for oxygen sensor terminals.

This bulletin describes the use of proper test probes to test the oxygen (O2) sensor connector
terminals equipped with the new TP2 style sensor. The recommended tool for these testing
procedures is the Miller Tool #6801.
CATEGORY 9
ENGINE
TSB#
MODELS
SUBJECT/DESCRIPTION
09-002-02
3/11/02
98 - 02 (BR)
Crankcase breather overflow.

This bulletin applies to 1998-2002 (BR) Ram trucks equipped with the 24-valve Cummins diesel
engine built after March 27, 1998 (engine serial number 56443872). Owners of these vehicles
may experience engine oil overflow from the front crankcase breather when the vehicle is operated off-road on an extreme downhill grade (37.5% or 22 slope/grade). Operation of this type
for extended periods of time can cause enough engine oil depletion to damage the engine. A kit
containing all components necessary to eliminate the oil overflow has been made available. If
the condition exists, perform the repair procedure outlined in this bulletin. The repair involves the
addition of a new breather kit.
09-008-02
10/21/02
98 - 02 (BR/BE)
Engine knock or rattle sound when climbing a long grade and towing a heavy trailer.
This bulletin applies to 1998-2002 Ram trucks equipped with the 24-valve Cummins diesel engine (sales code ETC or ETH). Owners may experience an engine knock or rattle sound when
climbing a long grade while towing a heavy trailer. If the condition exists, replace the engine
thermostat as outlined in the service manual. Note: Mopar 05015708AC is to be used exclusively
for this service bulletin. Use thermostat 05015708AB for all other 24-vlave Cummins thermostat
repairs.
09-004-06
03/31/06
03-06 (DR)
Accessory drive belt chirp at shutdown.

This bulletin applies to vehicles with diesel engine sales code ETH. A chirping sound may be
heard coming from the accessory drive belt when the engine is shut down. If a customer indicates
that the condition is present, the bulletin directs the technician to install an overrunning clutch
pulley on the generator.
56
CATEGORY 9
09-002-09
Rev. A
06/13/09
ENGINEcontinued
07-09 (DH/D1)
MIL illumination due to DTC P2262 - Revised diagnosis and repair procedures.
This bulletin applies to vehicle equipped with a Cummins 6.7-liter engine (sales code ETJ). The
bulletin supersedes technical service bulletin 09-002-09 dated 5/2/09. This bulletin discusses
revised diagnostic and repair procedures for DTC P2262 - Turbocharger Boost Pressure Not
Detected - Mechanical. Recent PCM calibration updates have improved the robustness to this
DTC through updated diagnostic strategies. As a result, many events which have no adverse
affects on drivability, emissions, or reliability will no longer set the P2262 fault.
As a result of recent PCM calibration updates, the proper repair for some P2262 faults is merely
to update the calibration, while others will require cleaning or replacing the turbocharger. Scan
Tool software includes a P2262 diagnosis test for this purpose. The new P2262 diagnosis test
must be used prior to performing any of the following:
Clearing codes
Updating the PCM
Beginning the turbocharger repair.
Based on the outcome of the P2262 diagnosis test, the Scan Tool will provide one of the following
as the proper direction for the appropriate repair. Service info and complete the repair as directed:
Update PCM flash calibration to the latest calibration. No repair required to the turbocharger.
Clean the turbocharger.
Update PCM flash calibration to the latest calibration and clean the turbocharger.
Replace the turbocharger.
Update PCM flash calibration to the latest calibration and replace the turbocharger.
CATEGORY 11
EXHAUST
TSB#
MODELS
SUBJECT/DESCRIPTION
11-002-07
9/25/07
07-08 (DH/D1)
2500/3500
Inspection and test procedures for the 6.7-liter diesel particulate filter (DPF).
This bulletin applies to vehicle equipped with a Cummins 6.7-liter engines (sales code ETF).
The customer may experience a malfunction indicator lamp (MIL) illumination, warning chime,
and an overhead electronic vehicle information center (EVIC) message that states Catalyst Full
Service Required. Investigation may reveal that the MIL illumination is due to one or more of the
following diagnostic trouble codes (DTCs):
P1451 Diesel Particulate Filter System Performance.
P2463 Diesel Particulate Filter Soot Accumulation.
P242F Diesel Particulate Filter Restriction Ash Accumulation.
The balance of the 10-page bulletin describes the inspection, test, repair, or replacement of the
DPF based on the severity of the accumulation in the DPF.
11-001-08
5/21/08
07-08 (DH/D1)
2500/3500
Cleaning the turbocharger on the Cummins 6.7-liter engine.

This 17-page bulletin describes the process of cleaning the turbocharger using Cummins Engine
Update Kit 10138-UPD to address excess soot accumulation. The procedure cleans the internal
components on the exhaust side of the turbocharger.
The bulletin goes hand-in-hand with TSBs 11-005-08 and 11-002-07 for detailed turbocharger,
engine and exhaust aftertreatment system repair procedures.
11-002-08
5/21/08
07-08 (DH/D1)
2500/3500
Inspections and test for the turbocharger on the Cummins 6.7-liter engine.
The customer may experience a malfunction indicator lamp (MIL) illumination due to diagnostic
trouble code (DTC): P2262 Turbocharger Boost Pressure Not Detected Mechanical.
If further codes of P1451, P2463 or P242F are present, the technician is referred to the repair
procedure listed in TSB 11-002-07. If the codes are not present, the repair and cleaning
procedures in this 8-page bulletin and TSB 11-001-08 are to be performed.
57
CATEGORY 11
11-001-09
7/23/09
07-09 (DH/D1)
EXHAUSTcontinued
Diesel Particulate Filter: Diagnosis and repair of DTCs P1451, P200C, P242F or black smoke
from exhaust.
This bulletin applies to vehicles equipped with a Cummins 6.7-liter engine (sales code ETJ). The
customer may experience a malfunction indicator lamp (MIL) illumination, warning chime and
an overhead electronic vehicle information center (EVIC) message regarding the aftertreatment
system and/or black smoke from the exhaust and/or a no start condition. Further investigation by
the technician may reveal that the MIL illumination and/or EVIC message is due to one or more
of the following diagnostic trouble codes (DTCs):
P1451 - Diesel Particulate Filter - System Performance
P242F - Diesel Particulate Filter Restriction - Ash Accumulation
P200C - Diesel Particulate Filter Over Temperature - Bank 1.
This bulletin provides revised diagnostic and repair procedures for DTCs P1451, P200C, P242F,
black smoke from the exhaust, or a no start condition due to a nonfunctional or plugged diesel
particulate filter (DPF).
11-002-09
8/5/09
07-09 (D1/DH)
Diesel particulate filter Stationary DeSoot.

This bulletin applies to D1/DH vehicles equipped with a 6.7-liter Cummins diesel engine (sales
code ETJ). Mobile DeSoot still applies to DC/DM vehicles equipped with the 6.7-liter Cummins
diesel engine (sales code ETJ). Stationary DeSoot has replaced Mobile DeSoot as the repair
for Diagnostic Trouble Codes P1451 and P2463. This bulletin provides the procedure to perform
Stationary DeSoot. This new procedure allows running the DeSoot in a secured area with the
vehicle unattended.
Stationary DeSoot can only be performed when the diesel particulate filter has exceeded a
specified soot threshold. The Diagnostic Scan Tool will not allow the procedure to operate unless
the threshold has been exceeded. If the vehicle does not have an active P1451, the soot in the
Diesel Particulate Filter is at a normal level and a scan tool initiated DeSoot is not needed.
CATEGORY 13
FRAME & BUMPERS
TSB#
MODELS
SUBJECT/DESCRIPTION
13-001-03
2/7/03
03 (DR)
Frame alterations.
This bulletin is to support the 2003 Body Builders Guide and presents guidelines that must be
followed during modifications or alterations to any 2003 Dodge Ram pickup frame. The following
general industry standard procedures are recommended for proper installation of special bodies
and/or equipment on the Ram pickup frame, such as fifth-wheel hitches, snow plows, etc. Failure
to follow these recommendations could result in damage to the basic vehicle and possible injury
to occupants. The information only bulletin gives the guidelines for welding and drilling of holes
into the frame.
CATEGORY 14
FUEL
TSB#
MODELS
SUBJECT/DESCRIPTION
23-018-02
5/20/02
00 - 01 (BR/BE)
Fuel cap difficult to remove.

This bulletin involves installing a revised fuel cap.
58
CATEGORY 14
14-002-02
Rev. A
6/13/03
FUELcontinued
98-02 (BE/BR)
Tampering with VP44 fuel pump on Cummins diesel engine.

This bulletin supersedes technical service bulletin 14-002-02, dated July 1, 2002. A number of
the VP44 fuel pumps have been returned through the warranty process as a result of tampering.
Generally, the customer complains that the vehicle dies while driving. When diagnosed, there
may or may not be Diagnostic Trouble Codes (DTC) present. When DTCs are present, there may
be one or more of the following:
DTC
124
146
361
363
364
375
P Code
P 0234
P 0217
P 0254
P 0251
P 1689
P 0602
Description
Turbo boost limit exceeded.
Decreased engine performance due to engine overheat condition.
Fuel injection pump fuel valve current too high.
Fuel injection pump mechanical failure fuel valve feedback circuit.
No communication between ECM and injector pump module.
ECM fuel calibration error.
The diagrams show the area where performance enhancing equipment is being connected into
the outboard wire of the two wires that control operation of the metering solenoid in the pump.
Another type of device places a connector between the metering solenoid harness and the upper connector on the pump. Telltale evidence can be seizure of the pump rotor, and/or cracked
or overstressed pump cam ring. The protective sleeve around the two wires may be rolled or
cut back to gain access for connection. Injection pumps that have been tampered with are not
warrantable.
14-005-02
11/8/02
03 (DR)
Fuel filter/water separator drain valve restriction.

This bulletin applies to vehicles equipped with a 5.9L Cummins 24-valve diesel engine (sales
code ETC or ETH), built before October 11, 2002. The problem described is that when the fuel filter/water separator drain valve is opened, nothing comes out. The bulletin outlines the procedure
for purging fluid out of the filter.
14-004-05
03 - 05 (DR)
Electronic fuel control (EFC) actuator available for service

This bulletin deals specifically with an engine surge at idle condition. The diagnostic procedures
are the same as those listed in TSB 14-003-05. The bulletin describes the repair procedure for
replacement of the electronic fuel control actuator.
14-003-06
Rev. A
10/27/06
03 - 07
(DR/DH/D1/DC)
Cummins diesel diagnostics.

This bulletin applies to vehicles with the 5.9 liter engine, sales code ETH or ETC.
Revised diagnostic procedures are available for the following conditions:
Engine cranks for a long time or will not start
White smoke and/or misfire after starting when the engine temperature is below 150 F
Engine surges at idle
Engine sounds
The 12-page bulletin gives the service technician a set of revised diagnostic procedures for the
fuel system. Each condition is discussed and possible causes are established. Step-by-step
instructions help the technician identify and repair the problem.
14-005-06
07/27/06
07 (DH/D1/DC)
5.9-liter and 6/7-liter Cummins diesel engines - correct low and ultra-low sulfur highway diesel fuel use.
This bulletin involves a discussion regarding the correct diesel fuel to use for either the 5.9-liter or
the 6.7-liter Cummins diesel engine (sales code ETH and ETJ respectively).
Dodge Ram trucks equipped with the 6.7L Cummins Turbo-Diesel engine are required by Federal
law to be fueled with ultra-low sulfur diesel fuel (model year 07.5). Early production 2007 Dodge
Ram trucks equipped with the 5.9 Cummins Turbo Diesel engine are allowed by Federal law to be
fueled with low sulfur diesel fuel, and are encouraged to fuel with ultra-low sulfur diesel fuel. The
new ultra-low sulfur highway diesel fuel enables vehicles equipped with the advanced emissions
control devices to achieve more stringent U/S EPA vehicle emissions standards.
59
CATEGORY 14
14-007-06
Rev. A
09/02/06
06-07 (DH/D1/DC)
FUELcontinued
Fuel and fuel filtering requirements for Cummins 5.9-liter and 6.7-liter engines.
This bulletin supersedes technical service bulletin 14-007-06, dated August 25, 2006.
This information-only bulletin involves a discussion regarding fuel system requirements. The
bulletin applies to vehicles equipped with a 5.9-liter High Output or a 6.7-liter Cummins Turbo
Diesel engine (sales codes ETH or ETJ respectively) that were built on or after March 07, 2006.
Bulletin highlights follow:
For the diesel engine system to operate at its peak performance a high level of fuel quality must
be maintained. Emission control and fuel delivery systems have advanced significantly. Care
must be taken to ensure that the fuel that is delivered to the engine fuel injection system is of the
highest quality possible and free of contaminants.
Significant components to fuel quality are: the initial quality of the fuel (as dispensed from the
service station fuel pump or bulk storage), on-vehicle fuel storage, and the on-vehicle fuel filtering
of the diesel fuel prior to the fuel injection process.
Use good quality diesel fuel from a reputable supplier. It is recommended that purchase of diesel fuel be
made from a service station that is known to dispense a high volume of highway diesel fuel.
Ultra low sulfur highway diesel fuel is required for use in Dodge Ram trucks equipped with a
6.7-liter diesel engine.
A maximum blend of 5% biodiesel (B5) is acceptable as long as the biodiesel mixture meets ASTM
specification D-975, D-975-grade S-15, and ASTM D6751. A biodiesel fuel blend that is higher
than 5% is not acceptable without additional fuel processing because these higher percentage
biodiesel blends contain excess amounts of moisture which exceed the water stripping capability
of the on-engine final fuel filter. Should a higher percentage biodiesel fuel be used, an auxiliary
water stripping filter will be required.
A maximum blend of 20% biodiesel (B20) can be used by government, military, and commercial
fleets who equip their vehicle(s) with an optional water separator, and adhere to the guidelines in
the Department of Defense specification A-A-59693.
Fuel conditioners (additives) are not recommended and should not be required if you buy good
quality fuel and follow cold weather advice supplied in the Owners Manual.
CATEGORY 18
VEHICLE PERFORMANCE
TSB#
MODELS
SUBJECT/DESCRIPTION
18-024-02
8/12/02
03 (DR)
Incorrect dual wheel identification in VIN, may effect replacement powertrain control module
(PCM) programming.
The sixth character in the VIN is used to identify the vehicle series (1500, 2500, 3500). Some
2003 vehicles equipped with dual rear wheels, built prior to July 15, 2003, may have an incorrect
number as the sixth character of the VIN. All vehicles equipped with dual wheels, sales code
WLA, should have the number 4 as the sixth character. This identifies the vehicle as a 3500
series equipped with dual rear wheels. The incorrectly built vehicles will have the number 3 in
that position. In the event that a Powertrain Control Module (PCM) would require replacement,
the new module requires that the complete VIN be input during the programming procedure. If
a new PCM is programmed with a 3 as the sixth character and it is equipped with dual rear
wheels, a conflict is likely to occur with the ABS module which will set an error code. Dual rear
wheel equipped vehicles require an ABS module calibrated for dual rear wheels. If PCM replacement is ever required, simply input a 4 instead of the 3 as the sixth character in the VIN when
programming the PCM.
60
CATEGORY 18
18-015-03
4/4/03
03 (DR)
Powertrain control module (PCM) shift quality improvements

The bulletin applies to vehicles equipped with a 5.9L standard output Cummins diesel
engine(sales code ETC) and a 47RE transmission(sales code DGP) built before December 31,
2002. The vehicle operator may find that the vehicle will not shift out of third gear at throttle between 50% and 90% until 70 mph. The repair involves selectively erasing and reprogramming
the powertrain control module (PCM) with new software.
18-027-03
7/4/03
03 (DR)
No throttle response, lack of power while towing and diagnostic trouble codes (DTC) P2638/
P0700.
The bulletin applies to vehicles equipped with a Cummins diesel engine (sales code ETC or
ETH) built on or before July 25, 2003. The vehicle may exhibit:
No throttle response if the engine is started with the Accelerator Pedal Position Sensor
(APPS) in an off-idle position (pedal depressed) and the transmission is shifted into
drive or reverse while the APPS remains in an off-idle position (pedal depressed),
causing the engine to remain at idle.
Lack of power while towing or hauling a heavy load with the transmission in overdrive
vehicles equipped with 47RE transmission.
The repair involves selectively erasing and reprogramming the Cummins CM845 engine control
module (ECM) with new software.
18-030-03
8/29/03
98.5-02 (BE/BR)
03-04 (DR)
Generic Cummins engine control module (ECM) procedure.

This bulletin applies to Ram trucks equipped with the 5.9L Cummins 24-valve diesel engine
(sales code ETC or ETH). Mopar is phasing out pre-programmed Cummins Diesel engine
control modules (ECM). New modules will no longer be pre-programmed when received from
Mopar. Replacement of future ECMs will require programming utilizing the DRBIII and TechCONNECT.
18-003-04
2/3/04
03 - 04 (DR)
Poor A/C performance, slow fuel gauge response, and diagnostic trouble codes PO341 and P1757.
This bulletin applies to vehicles equipped with a Cummins Turbo Diesel engine (sales code ETC
or ETH) with an engine serial number 57130284 or earlier and the engine date of manufacture on
or before December 10, 2003. The owner of the vehicle may describe slow fuel gauge response
after adding fuel. On California emission equipped vehicles, the problem is rapid A/C clutch
cycling and poor A/C performance until coolant temperature reaches 170. The repair involves
erasing and reprogramming the Cummins ECM with new software.
18-004-04
2/3/04
04 (DR)
Poor cab heat and/or slow engine warm-up in cold ambient temperatures.
This bulletin applies to DR vehicles equipped with a Cummins Turbo Diesel engine (sales code
ETC or ETH) and an automatic transmission, with an engine serial number 57130284 or earlier
and the engine date of manufacture on or before December 10, 2003. The vehicle operator may
describe poor cab heat and/or slow engine warm-up in cold ambient temperatures. A new feature
has been added that allows the vehicle operator to use the speed control switches to increase
the engine speed up to 1500 rpm in order to improve cab heat. The feature must be enabled
using the DRBIII. If the vehicle operator would like to have the feature enabled, perform the repair
procedure which involves erasing and reprogramming the Cummins ECM with new software.
18-007-04
2/24/04
04 (DR)
White smoke, engine stumble/misfire, or flat spot in engine performance.

This bulletin applies to vehicles equipped with a Cummins Turbo Diesel engine (sales code ETH)
with an engine serial number 57130285 through and including 57149668 and the engine date
of manufacture 12/10/2003 through and including 2/2/2004. The vehicle operator may describe:
White smoke during no-load engine acceleration between 2800 and 3000 rpm.
Engine stumble/misfire or flat spot during moderate accelerations between 1500 and 2500
rpm. May be accompanied by white smoke.
During cold ambient temperatures (30 or below) white smoke and/or engine stumble when
engine is started after an extended cold soak.
During cold ambient temperatures (30 or below) white smoke when restarting engine that
has not yet reached normal operating temperature.
If the vehicle operator describes or the technician experiences the problem, perform the repair
procedure which involves erasing and reprogramming the Cummins ECM with new software.
61
CATEGORY 18
18-033-04
8/20/04
98.5 - 02 (BR)
03 - 05 (DR)
Cummins engine control module (ECM) procedure.

Mopar is phasing out pre-programmed Cummins diesel engine control modules (ECM). New
modules will no longer be pre-programmed when received from Mopar. Replacement of future
ECMs will require programming at the dealership. This bulletin describes the programming
procedure.
18-041-05
12/20/05
06
Flash: engine performance/white smoke.

This bulletin applies to Ram trucks equipped with the 5.9L Cummins 24-valve diesel engine (sales
code ETH) built on or after June 9, 2005, through and including November 8, 2005. This bulletin
involves programming the PCM (Cummins) with new software. The software is designed to
reduce white smoke and improve engine performance after a cold start at ambient temperatures
below 60F and to improve oil pressure gauge operation.
18-001-06
Rev. A
7/12/06
06 - 07 (DR, DH, D1)

07 (DC)
StarSCAN StarMOBILE abort recovery procedures.

This information-only bulletin supersedes technical service bulletin 18-001-06, dated January
11, 2006, and provides guidelines to minimize flash reprogramming problems and recovery
procedure information for failed flash attempts.
18-003-06
Rev. A
09/27/06
05 - 06 (DH, D1)
Flash: long crank when starting and/or transmission shift and battery charging enhancements.
This bulletin applies to Ram trucks equipped with the 5.9L Cummins 24-valve diesel engine
(sales code ETH) built on or after January 01, 2005. The vehicle operator may experience
extended engine crank time in cold ambient temperatures on vehicles equipped with manual
transmissions. This flash also provides the following enhancements:
Improved start times for manual transmission vehicles
Improved automatic transmission shifting
Engine fan is activated if the coolant temperature sensor fails
Enhanced battery charging
This bulletin involves flash reprogramming the PCM (Cummins) with the software.
18-005-06
Rev. B
05/31/06
06 (DH/D1)
Flash: DTC correction, turbocharger protection, and clutch durability improvement.

This bulletin supersedes technical service bulletin 18-005-06 Rev. A, dated April 26, 2006. This
bulletin applies to Ram trucks equipped with the 5.9L Cummins 24-valve diesel engine (sales
code ETH) built on or after June 9, 2005, through and including May 31, 2006. The PCM software
has been revised to address the following issues:
A MIL may illuminate due to one or more of the following diagnostic trouble codes:
P0071 Inlet Air Temperature Sensor Rationality
P0111 Intake Air Temperature (IAT) Sensor Rationality
P0514 Battery Temperature Sensor Rationality
P0191 Fuel Pressure Rationality
Turbocharger durability improvement: Implemented an engine speed limitation when cold, to
protect the turbocharger bearings.
Clutch durability improvement: Implemented a minimum engine speed limitation when
launching vehicle from a stop, to protect the clutch.
This bulletin involves selectively erasing and reprogramming the PCM (Cummins) with new
software.
18-022-07
03/14/07
03 - 05 (DR)
Flash: 5.9L Turbo-Diesel engine system enhancements

This bulletin applies to vehicles equipped with a 5.9L Turbo Diesel engine (sales codes ETC
and ETH respectively). The bulletin supersedes 18-022-06 dated 07/13/06. The following
enhancements are included with this software update:
Improved engine cooling (radiator fan activation) and prevention of possible engine overheat.
When coolant temperature faults are present, the radiator fan is enabled (turned on) during
vehicle operation.
Correction to oil pressure reading when engine is operating at higher engine temperatures
above 195F.
62
CATEGORY 18
Improvement to the Temperature Sensor Rationality Test to prevent possible false test
failures and their following related diagnostic trouble codes:
DTC P0071 Inlet Air Temperature Sensor Rationality
DTC P0111 Intake Air Temperature (IAT) Sensor Rationality
DTC P0514 Battery Temperature Sensor Rationality.
Additional water-in-fuel (WIF) warning added to indicate that the operator has had a WIF
(DTC P2269) and has continued to operate the vehicle in excess of 500 miles without
draining the water from the fuel filter. The following is the new WIF DTC that has been added:
DTC P0169 WIF Too Long Error
Improvement to the fuel pressure rationality test to prevent false test failures and the related
DTC 0191.
This bulletin involves selectively erasing and reprogramming the engine control module with new
software.
18-038-06
12/05/06
07 (DC)
Flash: DTC P0471 Exhaust pressure sensor rationality on Cummins 6.7-liter Turbo Diesel.
This bulletin applies to vehicles equipped with a 6.7-liter engine (sales code ETJ) built on or
before October 05, 2006. The vehicle operator may experience a malfunction indicator lamp (MIL)
illumination due to diagnostic trouble code (DTC) P0471: exhaust pressure sensor rationality.
This bulletin involves selectively erasing and reprogramming the engine control module (ECMCummins) with new software.
18-001-07
01/06/07
06 - 07 (DH/D1)
Flash: check gauges lamp illuminates for alternator charging with DTC P2502, P2503, or P2509
This bulletin applies to vehicles equipped with a 5.9-liter engine (sales code ETH) built on or before
November 29, 2006. The customer may experience the illumination of the Check Gauges lamp
on the instrument panel cluster. Inspection of the gauges may reveal that the battery charging
gauge may read in the 11-volt range rather than in the 14-volt range. There may not be a Check
Engine/Malfunction Indicator Lamp (MIL) illumination.
Further diagnosis may reveal the following diagnostic trouble codes (DTCs) have been set:

P2502 Charging System Error Diesel

P2503 Charging System Output Low Diesel

P2509 Powerdown Data Lost Error Diesel
This bulletin involves selectively erasing and reprogramming the powertrain control module
(Cummins PCM) with new software.
18-009-07
Rev. B
07/13/07
07 (DC)
Ram truck 3500 Cab and Chassis Excessive soot accumulation in exhaust, PCM may not
reprogram, and other engine system enhancements.
This bulletin applies to Ram truck 3500 Cab and Chassis vehicles equipped with 6.7-liter Cummins
Turbo Diesel engine (sales code ETJ). This bulletin supersedes technical service bulletin 18-00907 Rev. A, dated May 16, 2007.
The vehicle operator and/or technician may experience one or more of the following conditions:
The technician may not be able to reprogram (flash) the PCM with new application software.
After extensive idling of the vehicle engine or if an intake air leak is present, the vehicle
operator may experience a MIL illumination and/or an electronic vehicle information center
(EVIC) message alert due to one or more of the following DTCs:
P1451 Diesel Particulate Filter System Performance.
P2463 Diesel Particulate filter Soot Accumulation
The vehicle operator may experience a MIL illumination due to one of the following DTCs:
P0101 Manifold Absolute Pressure Sensor Performance.
P0106 Boost Pressure Sensor Rationality.
P0191 Fuel Rail Pressure Sensor Circuit Performance.
Improved Water-In-Fuel (WIF) alert. To improve awareness that water has been detected in
the fuel system, the vehicle operator will be alerted to a five (5) chime alert versus a single (1)
chime alert.
This bulletin involves selectively erasing and reprogramming the powertrain control module
(PCM) with bootloader software and application software.
63
CATEGORY 18
18-030-07
04/26/07
04 - 07
(DR/DH/D1/DC)
Engine off-idle speed limit feature to protect turbocharger when vehicle is not moving.
This bulletin applies to vehicles equipped with a 5.9-liter or a 6.7-liter Cummins Turbo Diesel
engine (sales codes: ETC, ETH, or ETJ). This bulletin involves a discussion regarding an engine
control feature that limits engine off-idle speeds when the vehicle is not moving.
Dependent upon engine coolant temperature, the engine control module (ECM) will temporarily
limit the maximum engine speed when the vehicle is not moving. For automatic transmission
equipped vehicles the maximum engine speed is temporarily delayed when the vehicle speed is
less than one mph, and when the transmission selector is in either the neutral or park position.
For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed
when the vehicle speed is less than one mph. This ECM feature is used to protect the engine
turbocharger.
This delay in maximum engine and turbocharger shaft speed allows for sufficient oil lubrication to
the turbocharger shaft bearings which is important for long term turbocharger durability.
The maximum engine speed for the 5.9-liter engine is temporarily limited to 1,600 RPM when the
above conditions are met. The 6.7-liter engine speed is temporarily limited to 1,200 RPM when
the above conditions are met. The length of time that the maximum engine speed is temporarily
limited is dependent upon engine coolant temperature. For example, the delay can be up to 45
seconds at 35 or 7 seconds at 70.
18-033-07
Rev. B
06/28/07
07 (DH/D1)
Ram truck 2500 and 3500 Excessive soot accumulation in exhaust, PCM may not reprogram,
OBD readiness status and other engine system enhancements.
This bulletin applies to Ram truck 2500 and 3500 vehicles equipped with 6.7-liter Cummins
Turbo Diesel engine (sales code ETJ) built on or before June 11, 2007. This bulletin supersedes
technical service bulletin 18-033-07 Rev. A, dated June 12, 2007.
The vehicle operator and/or technician may experience one or more of the following conditions
and/or enhancements:
The technician may not be able to reprogram (flash) the PCM with new application software.
The vehicle may fail an emission inspection maintenance (I/M) test because two or more onaboard diagnostic (OBD) monitors report that they are not ready for testing. This condition may
cause the customer vehicle to fail an emissions I/M test. The following is a list of OBD Monitors
that may report as not ready for testing:
a. Non-Methane Hydrocarbon (NMHC) Catalyst Monitor.
b. Nitrogen Oxide (NOx) Absorber Monitor.
c. Exhaust Gas Temperature Sensor Monitor.
d. Electrical Charging System Monitor.
e. EGR System Monitor.
f. Oxygen Sensor Monitor.
After extensive idling of the vehicle engine or if an intake air leak is present, the vehicle
operator may experience a MIL illumination and/or an electronic vehicle information center
(EVIC) message alert due to one or more of the following DTCs:
P1451 Diesel Particulate Filter System performance
P2463 Diesel Particulate Filter Soot Accumulation
The vehicle operator may experience a MIL illumination due to one of the following DTCs:
P0106 Manifold Absolute Pressure Sensor Performance.
P242B Exhaust Gas Temperature Sensor Circuit Performance Bank 1 Sensor 3
P245A EGR Cooler Bypass Control Circuit Open
An intermittent rough engine idle and/or white smoke following initial engine start.
A throttle tip-in stumble at engine speeds of 1,300 to 2,100 rpm.
An engine hesitation at altitude of 5,000 feet between engine speeds of 1,200 to 1,600 rpm.
A turbocharger chuff-like sound during rapid deceleration.
This bulletin involves selectively erasing and reprogramming the Powertrain Control Module
(PCM) with bootloader software and application software.
64
CATEGORY 18
In October of 07 this TSB (and the number of fault codes addressed by the reprogramming of
the ECM) was superseded by a recall (Recall G30) of all 6.7-liter engines built to that date. The
TSB 18-033-07 was left in the magazine to give 6.7-liter owners data to see what the Recall
G30 scope of work entailed.
Then in December of 08 the G30 recall and the TSB 18-013-08 that described the proper repair
technique were updated again by TSB 18-013-08A.
18-037-07
Rev. A
07-20-07
07 (DH/D1)
68RFE Transmission DTC P0868 low line pressure.

This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7)
built on or before April 30, 2007. The customer may experience a malfunction indicator lamp (MIL)
illumination due to diagnostic trouble code (DTC) P0868-Low Line Pressure. This condition may
be due to the transmission control module (TCM) software or to a hardware circuit in the TCM.
This bulletin involves checking the transmission control module (TCM) to determine that it is in
proper working order and then selectively erasing and reprogramming the TCM with new software.
18-013-08
3/13/08
07 - 08
Engine system and exhaust aftertreatment system enhancements.

This bulletin applies to vehicles equipped with a Cummins 6.7-liter engine (sales code ETJ) built
on or before February 14, 2008. This bulletin discusses the G30 recall and the many drivability
issues that are addressed and covered in the G30 recall software update.
18-013-08
REV. A
12/4/08
07-09 (DH/D1)
Engine system and exhaust aftertreatment system enhancements.

This bulletin applies to vehicles equipped with a Cummins 6.7-liter engine (sale code ETJ) built
on or before November 27, 2008. This bulletin supersedes technical service bulletin 18-01308, dated March 13, 2008. This bulletin involves verifying that Emission Recall G30 - Replace
Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30
first, then verify the software level, and if necessary, selectively erasing and reprogramming the
Engine Control Module (ECM) with new software. Additionally, verify the software level, and if
necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module
with new software. With this latest ECM software release listed in this Service Bulletin, the
following symptoms have been completely addressed.
One of the following driveability conditions:
a. An intermittent rough engine idle and/or white smoke following initial engine start.
b. A throttle tip-in stumble at engine speeds of 1,300 to 2,100 rpm.
c. An engine hesitation at altitude of 5,000 feet between engine speeds of 1,200 to 1,600 rpm.
d. A turbocharger chuff-like sound during rapid deceleration.
The vehicle may fail an Emission Inspection Maintenance (I/M) Test because two or more OnBoard Diagnostic (OBD) monitors report that they are not ready for testing. This condition may
cause the customer vehicle to not pass an Emissions I/M test. The following is a list of OBD
Monitors that may report as not ready for testing:
a. Non-Methane Hydrocarbon (NMHC) Catalyst Monitor.
b. Nitrogen Oxide (NOx) Absorber Monitor.
c. Exhaust Gas Temperature Sensor Monitor.
d. Electrical Charging System Monitor.
e. EGR System Monitor.
f. Oxygen Sensor Monitor.
Malfunction Indicator Lamp (MIL) due to one or more of the following Diagnostic Trouble
Codes (DTCs):
a. P0101 - Mass Air Flow (MAF) Sensor Rationality
b. P0128 - Thermostat Rationality
c. U1421 - Implausible Ignition Key Off Time Received.
The latest ECM software includes a new extended idle feature to accommodate the extended idle
times present in some duty cycles. This feature may help to reduce the accumulation of soot in
the exhaust aftertreatment system when the engine is idling for an extended period of time.
65
CATEGORY 18
A number of improvements have been made to the engine diagnostics. Performing this Service
Bulletin completely will enable these diagnostic improvements.
To determine if the vehicle has the latest software, compare the software level to the following
notes:
If the vehicle in question is a 2007 model year vehicle, then compare the current ECM
software level part number to one of the following part numbers (or with a higher suffix):

55350430AZ (or higher) = DH 2500 6.7L Manual Transmission 50 State

55350435AZ (or higher) = DH 2500 6.7L Automatic Transmission 50 State

55351430AZ (or higher) = D1 3500 6.7L Manual Transmission 50 State

55351435AZ (or higher) = D1 3500 6.7L Automatic Transmission 50 State

62350430AR (or higher) = DH 2500 6.7L Manual Transmission 50 State

62350435AR (or higher) = DH 2500 6.7L Automatic Transmission 50 State

62351430AR (or higher) = D1 3500 6.7L Manual Transmission 50 State

62351435AR (or higher) = D1 3500 6.7L Automatic Transmission 50 State

72350430AF (or higher) = DH 2500 6.7L Manual Transmission 50 State

72350435AF (or higher) = DH 2500 6.7L Automatic Transmission 50 State

72351430AF (or higher) = D1 3500 6.7L Manual Transmission 50 State

72351435AF (or higher) = D1 3500 6.7L Automatic Transmission 50 State
Determine if the current CCN module level software part number is one of the following (or
with a higher suffix):

05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500)


18-035-08
9/13/08
07-08 (DH/D1)
MIL illumination due to P2000, P2A00 and/or P2A01.

The customer may experience MIL illumination. Further investigation by the technician may find
one or more of the following DTC(s) present:
P2000 - NOx Absorber Efficiency Below Threshold - Bank 1.
P2A00 - O2 Sensor 1/1 Circuit Performance.
P2A01 - O2 Sensor 1/2 Circuit Performance.
This bulletin involves verifying all TSBs related to high sooting issues have been properly
addressed, replacing both Oxygen (O2) Sensors, and wrapping the exhaust pipe in the area of
the FRONT O2 sensor.
18-001-09
1/21/09
07-09 (DC/DM)
(3500/4500/5500
Cab/Chassis)
Engine systems and exhaust aftertreatment systems enhancements.

This bulletin applies to vehicles equipped with a Cummins 6.7-liter engine (sales code ETJ) built
on or before January 13, 2009. This bulletin supersedes technical service bulletin 18-009-07 Rev.
B, dated July 13, 2007.
This bulletin involves verifying that the latest software has been installed on 2007 MY vehicles.
Selectively erasing and reprogramming the Engine Control Module (ECM). Selectively erasing
and reprogramming the Cab Compartment Node (CCN).
The latest PCM software will address the erroneous MIL illumination of the following faults:
P0191 - Fuel Rail Pressure Sensor Circuit Performance
P0128 - Thermostat Rationality
P0106 - Manifold Absolute Pressure Sensor Performance
P0524 - Engine Oil Pressure Too Low
P061A - ETC Level 2 Torque performance
P0607 - ECU Internal Performance
The latest PCM software will include the following operational and diagnostic improvements:
Improve engine cooling capability and prevention of over temp condition (P0217 - Coolant
Temperature Too High) when operating with snow plow. New feature that allows for customer
66
CATEGORY 18
selectable remote PTO speed (if equipped). The latest ECM software includes a new extended
idle feature to accommodate the extended idle times present in some duty cycles. This feature
may help to reduce the accumulation of soot in the exhaust aftertreatment system when the
engine is idling for an extended period of time.
To determine if the vehicle has the latest software, compare the following notes:
If the vehicle in question is a 2007 model year vehicle, then compare the current PCM

52300430AX (or higher) = DC 3500 6.7L Manual Transmission 50 State

55300434AX (or higher) = DC 3500 6.7L Automatic Transmission 50 State

61300430AK (or higher) = DC 3500 6.7L Manual Transmission 50 State

61300434AK (or higher) = DC 3500 6.7L Automatic Transmission 50 State

61301430AK (or higher) = DM 4500/5500 6.7L Manual Transmission 50 State

61301434AK (or higher) = DM 4500/5500 6.7L Automatic Transmission 50 State

71300430AH (or higher) = DC 3500 6.7L Manual Transmission 50 State

71300434AH (or higher) = DC 3500 6.7L Automatic Transmission 50 State

71301430AH (or higher) = DM 4500/5500 6.7L Manual Transmission 50 State

71301434AH (or higher) = DM 4500/5500 6.7L Automatic Transmission 50 State
Determine if the current CCN module level software part number is one of the following (or
with a higher suffix):

05172187AH (or higher) = 2007 DC (3500) / DM (3500/4500)

05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500)

05172529AG (or higher) = 2009 DC (3500) / DM (3500/4500)
18-024-09
8/6/09
07-09 (D1/DH)
CATEGORY 19
TSB#
19-003-02
4/15/02
19-005-03
8/29/03
MIL illumination and stationary DeSoot and other enhancements.

his bulletin applies to D1/DH vehicles equipped with a 6.7-liter Cummins engine (sales code ETJ)
built before May 5, 2009. The customer may experience:
An erroneous MIL illumination for P2262 - Turbocharger Boost Pressure Not Detected Mechanical.
Improved diagnostics for P2299 - Brake Pedal Position/Accelerator Pedal position
Incompatible.
An erroneous MIL illumination for P0402 - Exhaust Gas Recirculation (EGR) Flow
Excessive Detected.
An erroneous MIL illumination for P040B - EFR Temperature Sensor 1 Circuit Performance.
An erroneous MIL illumination for P0405 - EFR Position Sensor Circuit Low.
This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM)
with new software.
STEERING
MODELS
97-02 (BR/BE)
94 - 02 (BR/BE)
02 - 04 (DR)
SUBJECT/DESCRIPTION
Hissing sound coming from the power steering system on vehicles equipped with hydroboost
brakes.
A hissing sound may be present in the power steering system during steering maneuvers or
straight ahead driving. This bulletin involves replacing the power steering hoses connecting the
hydroboost to the power steering pump and gear.
Power steering fluid usage.
The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4
(part number 05013457AA/S9602) and it provides superior performance at both low and high
temperatures. Refer to the table to identify factory fill and the approved service power steering
fluid by year and model. From the table it is noted that the 94 to 02 truck uses part number
04883077/MS5931. MS9602 should not be mixed or used as a topping off fluid on systems
requiring MS5931.
67
CATEGORY 19
STEERINGcontinued
19-008-03
11/28/03
03 (DR)
Vibration in steering column.

A vibration may be felt in the steering wheel and/or the accelerator pedal on diesel engine vehicles
with the engine operating between 2000 and 2200 rpm. The vibration may be more pronounced
with the A/C compressor on. Operate the engine between 2000 and 2200 rpm. If the vibration is
present, perform the repair procedure which involves installing a power steering hose containing
a vibration damper.
19-010-04
11/29/04
04 - 05 (DR)
Power steering fluid contamination.

This information-only bulletin discusses the use of supplements to the power steering fluid. Do
not use fluids or supplements that contain Teflon as they will cause a restriction at the filter
in the power steering system. The power steering fluid used in Chrysler Group vehicles is an
engineered product. The addition of any unapproved fluids or supplements can interfere with the
proper function of the fluid and cause damage to the steering system. To ensure the performance
and durability of Chrysler Group steering systems, use only Mopar Power Steering Fluid +4,
ATF+4 automatic transmission fluid, or equivalent (MS-9602), in the power steering system.
19-003-05
5/3/05
03 - 05 (DR)
In and out movement in steering column.

This bulletin applies to vehicles built after December 1, 2003. If there is a small amount of
movement in the steering column when pulling the steering wheel toward you while seated in
the drivers seat, the TSB outlines the proper repair procedure which involves the installation of a
steering retainer kit to the steering column.
19-008-05
Rev. A
11/2/05
02 - 06 (DR)
Revised power steering system bleeding procedures.

This bulletin supersedes service bulletin 19-008-05, dated October 26, 2005. The bulletin
discussed that Mopar Power Steering fluid +4 or ATF+4 (MS-9602) is to be used in the power
steering system of DR vehicles. No other power steering or automatic transmission fluid is to
be used in these systems. Damage may result to the power steering pump and system if the
incorrect fluid is used. Do not overfill the power steering reservoir. If the air is not purged from the
power steering system correctly, pump failure could result.
CATEGORY 21
TSB#
MODELS
21-023-05
11/11/05
06
68
TRANSMISSION
SUBJECT/DESCRIPTION
Out of park sense alarm.
This information only bulletin applies to vehicles equipped with a 5.9L Turbo Diesel engine (sales
code ETH). This information only bulletin discusses an alarm for out of park transmission setting.
Vehicles with a diesel engine and an automatic transmission are equipped with an alarm that
warns the customer, upon exiting the vehicle, that the transmission is not in the Park position.
This feauture will only be functional under the following conditions:
engine running
foot off the brake pedal
drivers seat belt unbuckled
drivers door open.
When this feature is triggered the horn will sound and the high beams and turn signal lamps will
flash. This feature is standard equipment and cannot be disabled.
CATEGORY 21
21-006-06
3/11/06
\05 - 06
Transmission jumps out of reverse.

This bulletin applies to vehicles equipped with Cummins Turbo Diesel engines, sales code ETH
and G56 manual transmissions sales code DEG. A customer may experience the transmission
jumping out of reverse. If the customer indicates that the condition is present, perform the repair
procedure which involves replacing the reverse synchronizer.
21-010-06
4/14/06
All
Automatic transmission fluid usage ATF+4 (Type MS9602).

This bulletin supersedes technical service bulletin 21-004-04, dated March 16, 2004. ATF+4,
type 9602, is being used as factory fill for Chrysler Group automatic transmissions. ATF+4 is
recommended for all vehicles equipped with Chrysler Group automatic transmissions except
for those noted: AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/
PM vehicles equipped with Continuously Variable Transmission (CVT). ATF+4 is backward
compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles
that used ATF+3, ATF+2, or ATF+. Benefits:
Controls oxidation
Eliminates deposits
Controls friction
Superior properties for low temperature operation.
Mopar ATF+4 has exceptional durability. However, the red dye used in ATF+4 is not permanent;
as the fluid ages it may become darker or appear brown in color. ATF+4 also has a unique odor
that may change with age. With ATF+4 fluid, color and odor are no longer indicators of fluid
condition and do not necessarily support a fluid change.
21-003-07
02/09/07
Automatic transmission diagnostic tear down procedure.

This bulletin provides a procedure to determine repair versus replacement of an automatic
transmission assembly. Follow the proper repair procedure based on the transmission type. This
procedure is to be used after the transmission has been removed from the vehicle.
This bulletin supersedes technical service bulletin 21-008-06, dated 04/08/06.
This bulletin supersedes technical service bulletin 21-021-08, dated 09/17/08.
21-006-07
03/20/07
05 (DH)
Flash: New 48RE feature that allows normal shift schedule with full disable of 4th gear overdrive.
This bulletin applies to vehicles equipped with a 5.9-liter Cummins Turbo Diesel engine and a
48RE automatic transmission (sales codes ETH and DG8 respectively). A new 48RE transmission
feature is added that will allow normal shift schedule with full disable of 4th gear (overdrive gear),
when the customer selects the Over-Drive (O/D) switch.
Prior to the implementation of this new transmission feature, the use of the O/D switch changed
the automatic transmission shift schedule from a normal shift schedule to a tow/haul mode shift
schedule, and allowed 4th gear (overdrive gear) engagement.
This new transmission feature will not change the transmission shift schedule, but will allow full
4th gear overdrive disable (lock out). With this new feature the customer will have the normal
shift schedule with NO overdrive (4th gear).
This bulletin involves selectively erasing and reprogramming the Cummins Engine Control
Module (ECM) with new software.
21-009-07
5/24/07
04 - 07
48RE Transmission 1-2 shift hunt at light throttle.

The customer may experience a 1-2 shift transmission hunt during light throttle application. This
condition may be due to a governor pressure solenoid valve. This bulletin involves the replacement
of the governor pressure solenoid valve in the transmission valve body.
69
CATEGORY 21
21-014-07
All
Automatic transmission fluid usage ATF+4 (Type MS9602).

This bulletin supersedes technical service bulletin 21-010-06, dated 4/16/06. ATF+4, type 9602,
is being used as factory fill for Chrysler Group automatic transmissions. ATF+4 is recommended
for all vehicles equipped with Chrysler Group automatic transmissions except for those noted:
Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously
Variable Transmission (CVT), all vehicles equipped with a A568RC transmission (sales code
DG3), all vehicles with a Getrag MP56 (sales code DG5), and Grand Cherokees with the diesel
engine option. ATF+4 is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4
can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. Benefits:
Controls oxidation
Eliminates deposits
Controls friction
Superior properties for low temperature operation.
Mopar ATF+4 has exceptional durability. However, the red dye used in ATF+4 is not permanent;
as the fluid ages, it may become darker or appear brown in color. ATF+4 also has a unique odor
that may change with age. With ATF+4 fluid, color and odor are no longer indicators of fluid
condition and do not necessarily support a fluid change.
21-019-07
11/14/07
07 - 08 (DH/D1)
2500/3500
68RFE transmission harsh coast downshift and/or harsh 2-3 upshift.

This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7)
built on or before November 6, 2007. The customer may experience a harsh downshift from
the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around
25mph), the harsh downshift condition will usually occur as the vehicle decelerates to a speed
of about 10mph. If the transmission is in 2nd, 3rd, 5th, or 6th gear when the stop is initiated, the
condition will not be present. This may cause the condition to appear to be intermittent to the
customer. Because the harsh downshift may occur below 10mph, the customer may believe that
they are experiencing a harsh 2-1 downshift.
Some customers may also experience a harsh 2-3 upshift during normal acceleration. This
symptom is less common than the harsh coast downshift.
This bulletin involves selectively erasing and reprogramming the transmission control module
(TCM) with new software.
21-021-08
9/17/08
95-02 (BR/BE)
07-09 (D1/DC)
02-09 (DR/DH)
CATEGORY 22
TSB#
22-001-05
12/1/05
70
MODELS
00 - 01 (BR/BE)
02 - 06 (DR)
Automatic transmission diagnostic tear down procedure.

This bulletin provides a procedure to determine repair versus replacement of an automatic
transmission assembly. Follow the proper repair procedure based on the transmission type. This
procedure is to be used after the transmission has been removed from the vehicle.
WHEELS & TIRES

SUBJECT/DESCRIPTION
Chrome wheel care.
This information-only bulletin discusses chrome wheel care. Chrome wheels should be cleaned
regularly with mild soap and water or Mopar Car Wash Concentrate to maintain their luster and
prevent corrosion. Wash them with the same soap solution as the body of the vehicle. Care must
be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage
to wheels. Any of the Do Not Use items listed below can damage or stain wheels and wheel trim.
Wheel cleaners that contain hydrofluoric acid, biflouride compounds, sulfuric acid, or
phosphoric acid.
Any abrasive type cleaner.
CATEGORY 22
WHEELS & TIREScontinued

Any abrasive cleaning pad (such as steel wool) or abrasive brush.
Any oven cleaner.
A car wash that has carbide tipped wheel-cleaning brushes.
22-005-06
10/07/06
03 - 07
(DR/DH/D1/DC)
Front end shimmy on 4x4 vehicles when traveling over rough surfaces in the road.
This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. The customer may
experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a
bump or pothole. This bulletin involves verifying the condition of the vehicle front suspension and
steering components, and adjusting the front tire pressure.
If the customer experiences the above condition, perform the repair procedure which includes a
steering damper, tie rods and end links.
22-002-07
Rev. A
7/12/07
08 (DH)
2500
CATEGORY 23
Tire pressure monitor system (TPMS) Light Load reset switch and tire rotation caution.
This information-only bulletin provides information for new vehicle preparation, setting tire
pressures, rotating tires and setting the light load switch on vehicles with the tire pressure
monitoring system installed.
BODY
TSB#
MODELS
SUBJECT/DESCRIPTION
23-018-02
5/20/02
00-01 (BR/BE)
Armrest lid difficult to open.

The armrest lid may be difficult to latch or if latched, may be difficult to open. This may be
caused by an improperly adjusted latch pin. This bulletin involves adjusting the armrest lid
latch pin.
23-018-03
6/13/03
03 (DR)
Instrument panel whistle.

A whistling sound may be present coming from the front of the instrument panel near the bottom
of the windshield when the heater A/C blower is on. This may be caused by air escaping through
the holes in the center of the rivets that attach the VIN plate to the instrument panel. This can be
mis-diagnosed as a windshield air leak. If necessary, remove the instrument panel top cover and
apply a small drop of clear glass sealer to the center of each of the rivets to seal the rivet holes.
23-016-03
6/13/03
03 (DR)
Buzzing or vibrating sound coming from the front of the vehicle.

The description of the problem is a buzzing or vibrating sound coming from the front of the vehicle
at highway speeds. Open the hood and inspect the ID plate located on the radiator support. The
ID plate should be attached with four rivets. If there are only two rivets securing the ID plate, the
ID plate may be vibrating against the radiator support. The repair involves securing the ID plate
with additional rivets.
23-025-03
10/24/03
03 (DR)
Scratched aftermarket window tint film.

Customers who have installed aftermarket window tint film see scratches on the film on the
windows from contact with the door inner belt weather strip. Some vehicles may have been built
with the weather strip not having a coating of soft protective flocking on the surface that contacts
the window. The repair involves installing a revised door inner belt weather strip.
23-001-04
1/13/04
03 (DR)
Bug deflector wind whistle.

Some vehicles equipped with a factory installed hood mounted bug deflector may exhibit a
whistling sound coming from the front of the vehicle. The repair procedure involves installing
foam tape to the bug deflector.
71
CATEGORY 23
BODYcontinued
23-003-04
1/27/04
02 - 04 (DR)
Water leak at grab handle.

Water may enter the vehicle through the secondary door seal retainer or the roof seam, onto the
headliner and run down the A pillar, coming out at the grab handle. The repair involves sealing
holes in the roof panel.
23-004-04
04 (DR)
Cup holder binds or sticks.

If the cup holder binds, will not open, or only opens partially, the instrument panel trim should be
adjusted to provide clearance for the cup holder.
23-011-04
03 - 04 (DR)
Bug deflector loose/rattling.

This bulletin applies to vehicles equipped with a factory installed bug deflector, sales code MXB.
The bug deflector or air dam located on the front of the hood may become loose and rattle. The
deflector could become dislodged in an automatic car wash. The repair involves replacing the
bug deflector fasteners.
23-029-04
8/2/04
04 (DR)
Binding front power window.

This bulletin applies to vehicles equipped with trailer tow mirrors, sales code GPD or GPG.
Vehicle owners may experience the power window on the front door binding or slow to operate.
The corrective action involves lubricating the window channel and installing a spacer under the
outside mirror.
23-005-05
1/31/05
03 - 04 (DR)
Improved secondary door seal.

Mud or dirt may accumulate on the rocker panel, causing customers to complain that their
clothing gets dirty when they enter or exit the vehicle. This bulletin involves installing a new lower
secondary door seal.
23-022-05
4/2/05
05 - 06 (DR)
Low gloss interior trim.

This information-only bulletin discusses that all Chrysler, Dodge, and Jeep vehicles are designed
with a low gloss interior trim. This low gloss finish maintains pleasing aesthetics, and minimizes
glare of the instrument panel into the windshield. This low gloss finish should not be altered with
a medium or high gloss interior treatment solution such as MOPAR Protectors or other Armor
All-like products.
Instead, MOPAR Satin Select (part number 05174395AA) which has been specifically developed
to remove minor surface contamination and maintain the low gloss appearance, should be used
for interior trim treatment.
23-049-05
10/12/05
04 - 05 (DR)
Drip rail door seal torn.

The drip rail or secondary door seal may become torn from contact with the lower A pillar of the
front door. The repair involves replacing the secondary door seal with an improved seal.
23-009-06
2/14/06
04 - 05
Water leak at roof mounted marker lamps.

Water leaks may be present coming from the roof mounted marker lamps. New marker lamps
have been released which contain base gaskets. These marker lamps should be used in all
cases where water leaks are present at the marker lamps. These lamps will have to be replaced
in sets of five due to appearance differences. If water leak tests reveal that water leaks are
present at the marker lamps, perform the repair procedure.
23-014-06
3/8/06
All Chrysler Group

Vehicles
Windshield wiper blade maintenance.

Windshield wiper blades/elements are frequently replaced unnecessarily. If the wipe pattern
appears to be streaky or if there is chatter and no damage to the wiper blades/elements is
obvious, the following steps should be performed:
Use a soft cloth or sponge and squeegee and a solution of 50/50 alcohol and water, to wash
the windshield.
Raise the wiper blades off the glass and clean the wiper blade elements with a solution of
50/50 alcohol and water and a soft cloth, paper towel or sponge.
Return the wiper blades to their normal operating position. If the wipe pattern is still
objectionable, repeat several times. If the wipe pattern is still objectionable, replace the wiper
blades/elements.
72
CATEGORY 23
BODYcontinued
23-018-06
5/5/06
06 (DR)
Speaker buzz.
Customers may experience a buzzing sound coming from the door area when the radio is on.
This bulletin involves adding insulating tape to the inner door and door trim panel.
23-004-07
01/26/07
04 - 07 (DR)
Transit film removal.

This information only bulletin provides a transit film removal procedure.
23-021-06
Rev. A
08/09/06
07 (DR)
YES Essentials stain, odor, and static resistant fabric care.

This bulletin applies to vehicles equipped with YES Essentials stain, odor, and static resistant
fabric (sales code XGW). YES Essentials fabric is an easy-care material that repels and releases
soil to maintain the like-new appearance. Spills remain on the surface of the fabric to allow for
easy clean up and to prevent stains and odors. The material is antimicrobial and static resistant.
YES Essentials fabric may be cleaned in the following manner:
Remove as much of the stain as possible by blotting with a clean, dry towel.
Blot any remaining stain with a clean, damp towel.
For tough stains, apply Mopar Total clean, p/m 04897840AA, or a mild soap solution to a clean
damp cloth and remove the stain. Use a fresh, damp towel to remove the soap residue.
For grease stains, apply Mopar Multi-purpose Cleaner, p/n 05127532AA, to a clean, damp
cloth and remove the stain. Use a fresh, damp towel to remove the soap residue.
Do NOT use any solvents or fabric protectants on Yes Essentials fabric.
23-047-06
10/21/06
06 - 07 (DR/DH/D1)
Cracked windshield.
Windshield cracks caused by an impact from a foreign object (i.e. stone) are often difficult to
identify. The following assessment should be used to verify the presence of an impact chip on
the crack.
If no obvious impact chip is present, run a ball point pen along the crack and feel for a slight drop
or pit in the glass. If a slight drop or pit in the glass is present, this indicates a small impact caused
the crack. If the molding contains a witness mark or dent from an impact, inspect under the
molding for an impact chip in the same manner. Cracks caused by an impact are not warrantable.
23-010-07
3/24/07
06 - 07 (DR/DH/D1)
1500/2500/3500
Water leak due to small void in backlite sealer.

The customer may experience the presence of water on or under the rear area floor carpet.
This condition is likely due to water leaking past a small void in the adhesive used to retain the
backlite glass to the body panel. It is recommended that a flowable sealer be applied to seal a
small void in the backlite adhesive.
23-011-07
3/30/07
06 - 07 (DR/DH/D1)
1500/2500/3500
Glass keeper loose on back power sliding window.

The customer may notice that the glass keeper on the rear backlite has separated from the
glass. The bulletin gives directions for the proper repair procedure.
23-013-07
04/13/07
02 - 07
(DR/DH/D1/DC)
Trailer Towing Mirror New mirror glass locking tab, new removal procedure.
This bulletin applies to vehicles equipped with trailer tow mirrors (sales codes GPD or GPG) built
after April 16, 2007, and for any vehicle where service replacement of the mirror glass is required.
The trailer towing mirror assembly has a replaceable mirror glass. As part of the replaceable
mirror glass, a locking tab has been added to the plastic backing on the mirror glass. This change
has been made to vehicles built after April 16, 2007. This change is also being incorporated in
service replacement of mirror glass.
This bulletin involves a discussion regarding new removal procedure when replacing the mirror
glass on a trailer tow mirror.
73
CATEGORY 23
BODYcontinued
23-028-07
Rev.A
7/20/07
06 - 07 (DR/DH/D1)
1500/2500/3500
Buzz-like sound from front door speaker area when radio is on.
The sound in question will come from the interior door trim panel, in the area where the radio
speaker is mounted. This condition may be misdiagnosed as a bad radio speaker. The actual
cause is typically the interface between the door trim panel sound insulation and the door water
shield. The repair procedure involves the addition of sound insulation to the door panel.
23-035-07
08/08/07
06 - 08
(DC/DM/DR/DH/D1)
Exterior Lamp lens fogging.

Some customers may report that vehicle exterior lamp assemblies are fogged with a light layer
of condensation on the inside of the lenses. This may be reported after the lamps have been
turned on and brought up to operating temperature, turned off, and then rapidly cooled by cold
water (such as rain, or the water from a car wash). Lens fogging can also occur under certain
atmospheric conditions after a vehicle has been parked outside overnight (i.e., a warm humid day
followed by clear cool night). This will usually clear as atmospheric conditions change to allow
the condensation to change back into a vapor. Turning the lamps on will usually accelerate this
process.
A lamp that has a large number of water droplets visible on most internal surfaces indicates a
problem with the lamp sealing that has allowed water to enter the lamp. In this instance, the
customer is likely to report that moisture in the lamp is always present and never disappears. A
lamp that exhibits internal moisture permanently should be replaced.
This bulletin supersedes technical service bulletin 23-041-06, dated September 27, 2006.
23-017-08
5/10/08
08 (DR/DH/D1)
1500/2500/3500
Tailgate retaining cables appear to be of unequal lengths.

This bulletin applies to vehicles built on or before May 7, 2008. One of the two side tailgate
check cables may not be properly tensioned. This condition may cause the appearance that the
tailgate cables are of unequal lengths. The repair procedure involves setting the loose/longer in
appearance cable firmly into its seat.
23-046-07
10/30/07
06 - 08
(DR/D1/DC/DH)
Repair of etched paint.

This bulletin involves evaluating the paint condition on all horizontal panels for etching. If the
problem exists, the bulletin describes the proper repair procedure using sanding/buffing
techniques or spot paint refinishing.
CATEGORY 24
HEATING & A/C
TSB#
MODELS
SUBJECT/DESCRIPTION
24-009-02
10/28/02
90 - 04
All Chrysler Group
products using
R-134A refrigerant
A/C system leak detection.

Vehicles from the factory no longer have leak detection dye in the A/C system. To determine the
source of a R-134a leak, a leak tracer dye has to be injected into the A/C system.
24-003-03
5/23/03
90 - 04
All Chrysler Group
products
A/C system additives.

The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/
recharging equipment and/or A/C system components. Many federal, state/provincial and local
regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks through the use of approved leak detectors available
through Pentastar Service Equipment (PSE) and fluorescent leak detection dyes available
through Mopar Parts. Vehicles found with A/C system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended.
74
CATEGORY 24
HEATING & A/Ccontinued
24-004-03
6/13/03
03 (DR)
Defrost/door inoperative.
The defrost door may break at the pivot shaft causing inadequate travel. The system may not
completely close, causing a lack of air discharge out the floor vents and full discharge from the
defrost outlet. This may be caused by a broken actuator stop on the heater A/C (HVAC) housing. The bulletin describes the repair procedure for replacing the defrost door and the lower half
of the heater/AC housing.
24-021-05
12/16/05
06 (DR)
Mega Cab lack of air flow from rear seat heat duct.
This bulletin applies to 2006 Ram Truck Mega Cab built between 8/29/2005 and 8/31/2005.
The rear seat actuator rod could become disconnected from the actuator lever, causing the rear
seat heater door to become inoperative. This bulletin involves replacing the rear seat heat duct
actuator lever.
24-006-06
8/9/06
02 - 07 (DR)
A/C cooling coil odor.

This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the
cooling coil and housing. Some vehicle operators may experience a musty odor from the A/C
system, primarily at start up in hot and humid climates. This odor may be the result of microbial
growth on the cooling coil. During normal A/C system operation, condensation, bacteria and
fungi growth begins and odor results. If the operator describes, or the technician experiences, a
musty odor when operating the A/C system, perform the appropriate repair procedure based on
the vehicle model.
75

CATEGORY 8
ELECTRICAL
TSB#
MODEL
SUBJECT/DESCRIPTION
08-004-10
3/2/10
10 (D1)
10 (DJ)
09-10 (DS)
Radio video disable update.

This information-only bulletin describes the programming process used for allowing the front
seat video option to be displayed if the vehicle is in park (automatic) or the emergency brake is
on (manual).
09-018-10
7/29/10
10 (DJ)
09-10 (DS)
Left turn signal on trailer may be inoperative.

When verifying trailer turn signal function prior to towing a trailer, the customer may experience
a non functional left trailer turn signal. Check connector terminal number one. If there is silicone
in the connector use a suitable tool, such as a straight blade Exacto knife, to scrape the silicone
off the outside of the number one, left terminal.
CATEGORY 9
ENGINE
TSB#
MODEL
SUBJECT/DESCRIPTION
09-001-10
7/2/10
All diesel models
Dust-out diagnosis for Cummins diesel engines.

This information-only bulletin involves proper inspection procedures to determine engine failure
due to dust-out condition. Engines damaged due to the infiltration of dirt and/or debris through
the air intake system are not warrantable.
CATEGORY 14
FUEL
TSB#
MODEL
SUBJECT/DESCRIPTION
14-001-10
2/2/10
03-09 (DH, D1)
Electronic fuel control actuator (FCA) available for service/New diagnostics available for DTC
P0251.
This bulletin applies to vehicles equipped with a 5.9-liter Cummins Turbo Diesel engine. Should
the engine surge at idle or MIL illumination of code P0251 occur, follow the diagnostics in the
service bulletin. The bulletin involves replacing the FCA with a revised Mopar part number
05183245AA.
14-002-10
2/11/10
03-09 (DH, D1)

07-09 (DC)
Heavy duty filtration Mopar retrofit or add on parts available.

This bulletin applies to D1/DH/DR vehicles equipped with a 5.9-liter Cummins engine built
from 2003 model year and D1/DH/DC vehicles equipped with a 6.7-liter Cummins engine built
from 2007 model year. Several fuel system add-on or retrofit parts are available to enhance
the filtering capability for customers exposing their vehicles to extremely dirty conditions. The
description of parts available for Cummins diesel equipped vehicles is listed below:
6.7-Liter Changes
New fuel filter. This is the FS2 design. (5 and 10 micron filter-in-filter) fuel filter to retrofit earlier
models (shell and element).
68061633AA FS2 Element, fuel filter and shell.
68061634AA FS2 Element, fuel filter This filter to supersede the original 5183410AA
filter when supplies are exhausted.
6.7-Liter and 5.9-Liter Changes
Fuel tank vent hose. 5.9 and 6.7 add-on or upgraded fuel tank vent hose kit with vent cap.
68068997AA Fuel Tank Vent. Must be used in conjunction with the appropriate Fuel
Tank Vent Kit listed below:
68051906AA Kit, Severe Duty Fuel Tank Ventilation DC 52 Gallon Tank
68061341AA Kit, Severe Duty Fuel Tank Ventilation D1/DH 35 Gallon Tank
68061342AA Kit, Severe Duty Fuel Tank Ventilation D1/DH 34 Gallon Tank
5.9-Liter Changes
5.9 upgraded air filter. This filter is similar in design to the current 6.7-liter air filter. The part
number is: 53034249AA Element, Air Filter 2003-2007 5.9-liter
76
CATEGORY 18
VEHICLE PERFORMANCE
TSB#
MODEL
SUBJECT/DESCRIPTION
18-024-09
12/3/09
Rev. A
07-09 (D1, DH)
Diagnostic and System improvements and improved air filter minder.

This bulletin supersedes technical service bulletin 18-024-09, dated August 6, 2009. This bulletin
applies to D1/DH vehicles equipped with a 6.7-liter Cummins engine built before May 5, 2009.
This bulletin involves selectively erasing and reprogramming the engine control module (ECM)
with new software. Pickup trucks equipped with a 6.7-liter Cummins diesel have a number of
software improvements available. This latest bulletin will include:
EGR valve cleaning cycle.
DPF Snuffer feature to expand DPF temperature controls during deSoot.
DPF Super deSoot feature to enhance the deSoot process.
Improved air filter minder detection.
Added turbo cleaning scan tool service procedure available through a diagnostic scan tool.
This procedure is available with version 10.02 due out in December.
Many other enhancements.
18-016-10
4/30/10
07-08 (DH)
07-08 (D1)
CCN update required with J35 recall.

This bulletin applies to 07 and 08 vehicles equipped with a Cummins 6.7-liter engine. This bulletin
supersedes service bulletin 18-013-08 Rev. A, dated December 4, 2008. Many improvements
have been addressed with the latest engine control module (ECM) software addressed in Recall
J35. The cab compartment node (CCN) may require updating in conjunction with the Recall.
This service bulletin discusses the procedure used to update the CCN.
18-017-10
5/15/10
06 (DH) 2500 pickup

5.9-liter
06 (D1) 3500 pickup
5.9-liter
07 ((DH) 2500 pickup
5.9-liter
07 (D1) 3500 pickup
5.9-liter
07 (DC) 3500 Cab/
Chassis 6.7-liter
The problem addressed with this bulletin is that the truck will not pass a Smog Check On-Board
Diagnostic (OBD) Test or Inspection and Maintenance check up.
This bulletin applies to 2006 and 2007 vehicles equipped with a 5.9-liter Cummins engine (sales
code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or
Cab Chassis equipped with a 6.7-liter Cummins engine (sales code ETJ) built prior to January
11, 2007. This bulletin supersedes service bulletin 18-038-09, dated December 19, 2009. This
revised bulletin will cover federal emissions (EPA) certified vehicles only. Vehicles equipped with
CARB (California) emissions have been removed and are addressed in Recall K01, dated May
2010.
The instructions in the bulletin tell the technician how to selectively erase and reprogram the
Engine Control Module (ECM) with new software.
18-020-10
6/10/10
07-10 (DC)
08-10 (DM)
Engine systems and exhaust aftertreatment systems enhancements.

Cab chassis trucks equipped with a 6.7-liter Cummins engine have a number of software
improvements available. This latest service bulletin (which supersedes 18-038-06 and 18001-09) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL)
illumination:
P000F Fuel System Over Pressure Relief Valve Activated
P0087 Fuel Rail Pressure Too Low
P0106 Manifold Absolute Pressure Sensor Performance
P0191 Fuel Rail Pressure Sensor circuit Performance
P1011 Fuel Pump Delivery Pressure Too Low
P2299 Brake Pedal Position/Accelerator Pedal Position Incompatible
P2262 Turbocharger Boost Pressure Not Detected Mechanical
The bulletin involves selectively erasing and reprogramming the ECM.
77
CATEGORY 19
FRONT SUSPENSION
TSB#
MODEL
SUBJECT/DESCRIPTION
19-002-10
1/23/10
08-09 (DM)
Steering wander.
While traveling on a straight stretch of highway, a customer may feel the need to provide steering
input to correct a vehicle wander condition. This bulletin applies to 4x2 vehicles built before
August 8, 2009. This bulletin involves inspection or replacement of suspension components and
revised caster specifications to improve road feel and correct a vehicle wander condition. If the
vehicle operator describes the symptom/condition, perform the repair procedure.
19-004-10
5/29/10
09 (DH)
Steering Wander
While traveling on a straight stretch of highway, a customer may feel the need to provide steering
input to correct a vehicle wander condition. This bulletin applies to 4x4 vehicles built before
February 4, 2009. This bulletin involves installing an Intermediate steering shaft kit, part number
05165725AA.
CATEGORY 21
TRANSMISSION
TSB#
MODEL
SUBJECT/DESCRIPTION
21-003-10
5/12/10
07 (DC)
MIL illumination due to transmission related DTC P0711 or P0776.

This bulletin applies to 2007 3500 Chassis Cab models equipped with a 6.7-liter diesel engine
and an AS68RC automatic transmission. This bulletin supersedes service bulletin 21-019-08,
dated August 2, 2008. The customer may experience a malfunction indicator lamp (MIL) due to
one or both of the following diagnostic trouble codes:
P0711 Transmission Temperature Sensor 1 Performance
P0776 Pressure Control Solenoid B Performance.
This bulletin involves verifying software levels in the transmission control module (TCM) and the
engine control module (ECM). Then, as necessary, selectively erasing and reprogramming the
TCM and possibly the ECM.
CATEGORY 23
BODY
TSB#
MODEL
SUBJECT/DESCRIPTION
23-006-10
3/10/10
10 (D2)
10 (DJ)
09 (DS)
Hood creaking and squeaking sound.

The customer may experience a creaking and or squeaking sound from the hood area when
turning the vehicle and or going over rough terrain. Inspect the hood, and if a squeaking or
creaking sound is observed when pressing the front of the hood, perform the repair procedure,
which calls for the addition of anti-squeak tape to the underside of the hood.
78
CATEGORY 25
EMISSIONS CONTROL
TSB#
MODEL
SUBJECT/DESCRIPTION
25-001-09
10/20/09
07-09 (DH/D1)
MIL Illumination due to P2000, P2A00 and/or P2A01.

This bulletin supersedes service bulletin 18-035-08 dated September 13, 2008. This bulletin
applies to vehicles equipped with a 6.7-liter Cummins diesel engine. The customer may
experience MIL illumination. Further investigation by the technician may find one or more of the
following DTC(s) present:
P2000 NOX Absorber Efficiency Below Threshold Bank 1.
P2A00 O2 Sensor 1/1 Circuit Performance.
P2A01 O2 Sensor 1/2 Circuit Performance.
This bulletin involves verifying all TSBs related to high sooting issues have been properly
addressed, inspecting both Oxygen (O2) sensors and either cleaning the sensors or replacing
sensors, and installing an O2 Sensor Blanket/Shield on the exhaust pipe in the area of the front
O2 sensor.
25-001-10
7/9/10
11 (DD)
11 (DP)
Diesel exhaust fluid.

This bulletin provides information regarding the diesel exhaust fluid (DEF) vehicle delivery fill
guidelines. The vehicle is equipped with a Low DEF warning system that notifies the driver
when the level of DEF drops below approximately 2.5 gallons. The warning system includes
warning messages displayed by the EVIC and audible chimes. The first level warning displays
the message Refill DEF Engine Will Not Restart In XXX Miles. If the vehicle is driven too long
with low DEF, the message Refill DEF Engine Will Not Start will be displayed. At that point,
the engine will no longer restart if it is shut off. A minimum of 2.5 gallons of DEF will need to be
added in order to be able to restart the engine.
The following diagnostic trouble code may be displayed on a Diagnostic Scan Tool if the level
of DEF was low.
P203F (Diesel Exhaust Fluid) Reductant Level Too Low
When this code is set, the Powertrain Control Module (PCM) initiates a countdown that will
inhibit an engine restart if the DEF system is not serviced within 500 miles .
P1C70 SCR Error Detected Engine Disabled
When this code is set, the PCM commands the EVIC to display the Refill DEF Engine Will
Not Start message. The message will continuously display when the counter reaches zero,
and will be accompanied by a periodic chime. The engine will not start after it has been turned
off unless up to 2.5 gallons of DEF is added to the tank.
DEF has a temperature dependent shelf life that shortens when exposed to elevated temperatures.
As temperatures increase, the Urea in the DEF degrades. As the concentration degrades, the
urea will become less effective at reducing NOx levels in the SCR catalyst. The following chart
provides the approximate shelf life of DEF Versus temperature.
Temperature Estimated Useful Life

32F (0C)
Indefinite

50F (10C)
75 Years

68F (20C)
11 Years

86F (30C)
23 Months

95F (35C)
10 Months

104F (40C)
4 Months

122F (50C)
1 Month

140F (60C)
1 Week
79

CATEGORY 7
COOLING
TSB#
MODEL
SUBJECT/DESCRIPTION
07-003-10
9/9/10
07-10 DC/DM
11 DD/DP
High coolant temperatures on vehicles equipped with snow plows.

Customers that operate their vehicle with a snow plow attached to the vehicle may cause the
airflow passing through the radiator to be disrupted resulting in higher than normal engine
temperatures. The Cummins ECM is equipped with software that can fully engage the fan
clutch to allow an increase of airflow through the radiator. Customers can initiate the fan clutch
operation by performing the following button sequence:
Turn the ignition key to the run position or start the truck.
Simultaneously press and release the Cruise Control Cancel button/lever and the
Exhaust Brake button. Repeat this sequence four times within five seconds. The chime
will sound twice as an audible indicator that the function is engaged.
To disable the function, repeat the same procedure. The chime will sound four times as an
audible indicator that the function is disengaged.
Note: 07-09 truck engine ECMs were not equipped with the fan engagement software. These
engines would require the latest software update (18-020-10) in order to have the fan-on
capability.
07-002-11
8/13/11
11 DJ/D2
Transmission cooler hose weepage.

This bulletin applies to vehicles equipped with the Cummins engine and an automatic
transmission built between September 20, 2010, and January 17, 2011. Some of the listed
vehicles have been built with a transmission cooler hose that may experience fluid weepage.
Inspect the upper transmission cooler hose (Hot side line that runs near the battery) for date
code 2440. If the upper transmission cooler hose has date code 2440 on the hose, verify
whether or not the hose was built between 21:14 23:16 (Time Stamp). The date code may be
on the lower side of the hose. It may be necessary to use a mirror or rotate the hose.
This bulletin involves inspecting the upper transmission cooler hose for a specific date code and
time stamp. If found within the suspect range, the transmission cooler hose must be replaced.
08-014-10
6/29/10
10 D1/DJ
Radio locks up.

This bulletin applies to vehicles equipped with a radio with sales code REN, REZ. The problem
may be that the radio will not change stations or frequency intermittently. The only function that
will be available is volume control. The repair involves upgrading the software of the REN/REZ
radio.
08-026-10
Rev. A
12/18/10
11 DD/DJ/DP/D2
Park assist system for message clarity and false messages on 4x4 models.
This bulletin applies to vehicles built with the Parksense Rear Park Assist (sales code XAA).
Customers may not understand the EVIC message display Blinded. This indicates that the
Parksense Rear Park Assist sensors require cleaning. The EVIC flash will change the display
to indicate Clean Sensors. The EVIC may display the message Press 4 Low when a shift
into 4x4 is not allowed. This message has no meaning on these vehicles. The EVIC flash will
prevent this message from being displayed.
This bulletin involves reprogramming the EVIC with new software.
80
CATEGORY 8
ELECTRICAL
TSB#
MODEL
SUBJECT/DESCRIPTION
08-028-10
Rev. A
11/2/10
10 DJ/DX/D2
RBZ radio software enhancements.

This bulletin applies to vehicles built with a radio that has a sales code RBZ. The customer may
experience one or more of the following problems:
The display may appear to be dimly lit when in backup camera mode (if equipped).
Screen fonts too small or unclear.
Video playback, display too bright.
Audio playback, sound quality/frequency response could be improved.
Hands free call information does not display caller ID.
Bluetooth streaming audio information is incomplete.
The repair involves upgrading the software on the RBZ radio.
08-001-11
Rev. A
3/5/11
10-11 DJ/D2
Radio software enhancements.

This bulletin applies to vehicles built with a radio/navigation units with sales codes RER, REW
or REP. The problems experienced:
The radio may lock up when a U-Connect call ends, this may cause battery drain.
Intermittent/no sound from audio system.
Repeated Updating Channels message when in satellite radio mode.
Losing Bluetooth connection intermittently and not displaying accurate caller ID information
when using U-Connect.
This bulletin involves upgrading the software on the RER, REW, or REP Radio.
08-003-11
Rev. B
3/17/11
10-11 DD/DJ/DX/D2
11 D2
Exterior mirror courtesy lamps stay on longer than the customer desires.
This bulletin involves checking the software version and, if necessary, flash reprogramming
front door control modules with new software. This bulletin supersedes bulletin 08-003-11
revision A. This bulletin applies to vehicles equipped with exterior mirror courtesy lights (sales
code LEC) built between January 1, 2010, and December 13, 2010.
08-018-11
Rev. A
7/1/11
10-11 DJ/D2
Static, squeal, no sound, or intermittent sound from speakers.

This bulletin applies to DJ and D2 vehicles built between July 15, 2010, and November 30,
2010, equipped with 9 amplified speakers w/subwoofer (sales code RC3) or 9 amplified
speakers (sales code RCZ). This bulletin also applies to DJ, and D2 vehicles built between July
15, 2010, and February 28, 2011, equipped with Premium I speakers (sales code RCK).
The repair involves removing and replacing the amplifier.
08-024-11
Rev. A
7/1/11
11 DD/DJ/DP
Flash: Intermittent no start or intermittent RKE function.

This bulletin applies to DD, DJ, and DP vehicles built before April 7, 2011, equipped with remote
keyless entry (sales code GXM). This bulletin involves flash reprogramming the wireless ignition
node (WIN) with new software. The service flash corrects the following conditions
Intermittent no start.
Intermittent RKE.
The above conditions may be caused by a software lockup in the module. The lockup condition
may be cleared by removing the reinserting fuse M27. Flash reprogramming the WIN will
correct these conditions.
08-015-11
4/6/11
11 DJ/D2/DD/DP
Loss of communications with the hands free module (HFM).

If there is a loss of the hands free module function the service bulletin involves performing a
USB service flash of the hands free module.
08-033-11
6/22/11
11 DJ/D2/DD/DP
Intermittent diagnostic trouble code P0201 Fuel injector 1 circuit open/closed.

This bulletin applies to a small number of vehicles equipped with the Cummins engine built
between March 1, 2011, and March 11, 2011. Suspect vehicles may intermittently set DTC
P0201 Fuel injector 1 circuit open/closed. This bulletin involves replacing terminal number 26
from the powertrain control module (PCM) 76-way connector.
08-049-11
8/12/11
11 DJ/D2/DD/DP/DX
Front overhead ambient light intermittent operation or inoperable.

This bulletin applies to vehicles built between February 11, 2011, and March 9, 2011. If there is
intermittent or no operation of the front overhead light this bulletin explains how to remove and
repair the light.
81
CATEGORY 9
ENGINE
TSB#
MODEL
SUBJECT/DESCRIPTION
09-004-10
11/11/10
11 DJ/D2/DD/DP
Incorrect engine oil level indicator.

Cummins engines are equipped with an engine oil level indicator that identifies a Safe region
on the end of the indicator. Some vehicles were equipped with an engine oil level indicator
end that had Add, Cold, Hot, and Do Not Add increments on the end. These engine oil level
indicators will need to be replaced. This bulletin involves inspecting the engine oil level indicator
and replacing it if found to have an incorrect indicator end.
CATEGORY 13
13-001-11
5/13/11
10-11 DJ
CATEGORY 14
14-005-10
9/21/10
10-11 DJ/D2
CATEGORY 18
18-004-11
Rev. A
2/18/11
10 DJ/D2
FRAME & BUMPERS

Front axle skid plate to oil pan contact.
This bulletin applies to vehicles equipped with 6.7-liter Cummins engine and TRX package
(sales code AMW) built after September 1, 2009, and built prior to September 23, 2010. The
front axle skid plate may contact the oil pan during extreme off road usage. The repair involves
inspection of the oil pan and if necessary replacement of the front skid plate and oil pan.
FUEL SYSTEM
Fuel filler housing pops out of sheet metal.
This bulletin applies to vehicles equipped with a single wheel rear axle only built before August
9, 2010. The customer may notice that the fuel filler housing has popped out from the body on
one side or the other. This bulletin involves removing the fuel filler housing to file some material
off of the tabs that will not lock into place. If tab(s) are broken it will be necessary to replace the
fuel filler housing and it still may be necessary to file some material off of the tab(s) that will not
lock into place.
VEHICLE PEFORMANCE
Diagnostic and system improvements.
This bulletin applies to trucks equipped with a 6.7-liter Cummins diesel. The bulletin describes a
number of software improvements/enhancements that are available:
P046C EGR position sensor performance
P051B Crankcase pressure sensor circuit range/performance
P0101 Mass air flow sensor A circuit performance
P2002 Diesel particulate filter efficiency below threshold
P2196 O2 sensor 1/1 out of range low
P245B EGR cooler bypass status line intermittent
P2262 Turbocharger boost pressure not detected mechanical
P2271 O2 sensor out of range low
with new software.
82
CATEGORY 18
VEHICLE PEFORMANCE...continued
TSB#
MODEL
SUBJECT/DESCRIPTION
18-029-11
5/28/11
11 DD/DP
Engine systems and PTO enhancements.

This bulletin applies to vehicles equipped with a Cummins engine built before January 1, 2011.
These cab chassis trucks have a number of software improvements available. This latest
service bulletin will include:
Improvements to prevent unnecessary malfunction indicator lamp (MIL) illumination for:
P0524 fault for low oil pressure, set during low ambient temperatures.
P051B fault for crankcase pressure.
Enhanced diagnostics for:
Variable geometry turbocharger.
Fuel level sensor.
Other updates:
Low diesel exhaust fluid (DEF) level EVIC messaging strategy changes.
Diesel exhaust fluid (DEF) system tampering EVIC messaging strategy changes.
Oil change monitor updated for easier reset (same basic procedure, easier to reset).
Scan tool display updates.
Enable mobile PTO capability.
Correct operation of remote PTO.
Correct EVIC messaging related to DEF level reporting.
System robustness improvements.
DEF tank level reporting erroneously at high DEF tank level. When DEF tank is overfilled,
the EVIC may display low fluid level (20-22%).
with new software.
CATEGORY 19
STEERING
19-001-11
Rev. A
8/9/11
08-10 DM
11 DP
10-11 DJ/D2/DD
06-09 DH/D1
07-09 DC
05 DH
03-04 DR
Tie rod ball stud housing alignment procedure.

This bulletin describes the proper procedure to ensure parallel alignment of the right and left
steering tie rod ball stud housings. The bulletin applies to 4x4 models of the 2500/3500 pickup
truck and to all 3500/4500/5500 Cab Chassis trucks which have a solid front axle. The overview
of this repair procedure: The right-to-left tie rod ball stud housings must be aligned parallel to
one another and not exceed +/-3 degrees of combined parallelism. This procedure is required
any time service is performed to either the tie rod or when performing a front end alignment or
toe set procedure. Failure to properly perform the parallel alignment procedure may lead to tie
rod damage.
19-003-11
2/2/11
10-11 DJ/D2
11 DD
Steering honk and/or groan sound during low speed parking lot maneuvers.
This bulletin applies to vehicles equipped with 6.7-liter Cummins engine built prior to November
23,2010. The customer may experience a honk and/or groan sound coming from the steering
system during low speed parking lot maneuvers. This bulletin involves inspecting and, if
necessary, replacing the power steering gear. This bulletin applies to 4x4 models of the
2500/3500 pickup truck.
83
CATEGORY 20
BODY
TSB#
MODEL
SUBJECT/DESCRIPTION
23-024-11
7/12/11
11 DD/DP
10-11 DJ/D2
09-10 DM/DC
09 DH/D1
Whistle and/or high pitch windnoise at door near windshield A-pillar.

This bulletin applies to vehicles built before April 18, 2011. The customer may experience
whistle and/or high pitch windnoise at door near windshield A-pillar. This bulletin involves
installing a foam stuffer block into door weatherstrip.
CATEGORY 25
25-002-10
9/22/10
84
11 DD/DP
EMISSIONS CONTROL
Misassembled diesel exhaust fluid engine coolant control valve.
This bulletin applies to vehicles equipped with the Cummins engine built between March 3,
2010, and July 19, 2010. Some trucks may have been built with a DEF engine coolant control
valve that may be internally misassembled which may not be able to completely shut the flow
of coolant passing through the coolant tubes in the DEF tank. This allows the DEF temperature
to rise above its normal operating range. DEF that has been exposed to elevated temperatures
can cause the DEF to degrade. This bulletin involves replacing the diesel exhaust fluid (DEF)
engine coolant control valve assembly. Some of the involved vehicles may also require draining
and adding DEF.

CATEGORY 8
ELECTRICAL
TSB#
MODEL
SUBJECT/DESCRIPTION
08-011-12
2/8/102
12 DJ/DD/D2/DP
Radio anti-theft codes.

Starting in model year 2012 radios will come equipped with an anti-theft feature. Once a radio is
installed in a vehicle, it learns the vehicles VIN and cannot be used in another vehicle unless an
anti-theft code is applied.
This information only TSB tells the dealer how to obtain the radios anti-theft code. This bulletin
also supersedes bulletin 08-051-11 dated 8/20/11 by providing updated service information.
Editors Comments Radios
Have you tried to restore a car with a coded radio? Ive been playing with BMW coded
radios from cars that are now 25 years old. What a pain in the tail.
This brings several questions to mind: In todays market, where a replacement can be
purchased for $69, does theft occur that often? Why is Chrysler 30 years behind the theft
code thing? What implications will this have to Joe-second-owner/Joe-restoration who
does not have TSB 08-011-12 to tell him how the dealer can unlock a code?
Geez.
CATEGORY 9
09-004-11
9/12/11
ENGINE
Any Cummins diesel

engine that is still
covered under the
provisions of the
factory warranty.
Dust-out diagnosis for Cummins diesel engines.

This information only bulletin involves proper inspection procedures to determine engine
failure due to dust-out condition. Engines damaged due to the infiltration of dirt and/or debris
through the air intake system are not warrantable.
Engines that exhibit particular symptoms that may have been caused by improper air filtration
and/or lack of proper maintenance. Some of these symptoms are listed below (not limited to):
Knocking
Hard or no start
Low power/poor performance
Oil consumption
Lower end bearing failure
Broken rod
Smoking
Blow-by (rings not sealing)
Oil on turbo (dust damage to seal/bearing)
This nine-page bulletin supersedes bulletin 09-001-10 dated 7/2/10 and gives the service
network an easy to print/easy to follow diagnosis procedure. The highlights:
Major mechanical damage can be caused by fuel, fuel injectors, up-rate kits or programmers.
Inspect vehicle for any device that adds more power (fuel), which may damage the engine
mechanically. Check for any aftermarket power enhancer box or downloader. Repairs
performed on engines with failures caused by these devices do not qualify for warranty
coverage.
Inspect for aftermarket cold air performance air filter housing, duct work and/or air filter type
(wrong style air filter which may be used in a stock air filter box).
Vehicles with extremely large amounts of visible dirt accumulation are candidates for dust out
damage if not properly maintained or use of improper filters. Engines with excessive cylinder
and/or ring wear will consume excess oil. Look for oil spilled near filler on valve cover which
may indicate oil has been (or is) added often.
As mentioned, the bulletin continues for nine-pages that show the cause/effect from lack of
proper air filtration.
85
CATEGORY 9
ENGINE...continued
Editors Comments Dust Out
If you spend a day answering the tech line at Genos Garage you would be surprised at
the number of phone calls asking about air filters and cold air boxes.
The staffs answer: If you value your rights to warranty consideration, leave the air intake
system alone.
Prior to this TSB there was the 09-001-10 TSB. Prior to these TSBs there was the K&N
story, the short version being that testing was done on this filter in 1999 by Dodge and
Cummins. Prior to the test, K&N was the number two selling item at Genos Garage.
After the test, K&N filters were no longer offered by Genos. However, folks still want to
know more as aftermarket advertising does an admirable job of selling these parts. So, if
you need to help control exhaust gas temperatures due to the high horsepower you are
making, you should consider a cold air box and a multi-layer filter. The Genos folks do
sell a multi-layer filter. See TDR Issue 56, page 150 and Issue 59, page 130 for the cold air
box story. See TDR Issue 34, page 105 and Issue 77, page 56, for the K&N story.
CATEGORY 14
FUEL SYSTEM
TSB#
MODEL
SUBJECT/DESCRIPTION
14-004-11
4/1/11
03-09 (D1/DH/DR)
07-10 (DC)
Heavy duty filtration Mopar retrofit or add on parts available.

This bulletin applies to D1/DH/DR vehicles equipped with a 5.9-liter Cummins engine built
from 2003 model year and D1/DH/DC vehicles equipped with a 6.7-liter Cummins engine built
from 2007.5 model year. Several fuel system add-on or retrofit parts are available to enhance
the filtering capability for customers exposing their vehicles to extremely dirty conditions. The
description of parts available for Cummins diesel equipped vehicles is listed below:
5.9-Liter Changes Air Filter
5.9 upgraded air filter. This filter is similar in design to the current 6.7-liter air filter. The part
number is: 53034249AA Element, Air Filter 2003-2007 5.9-liter
6.7-Liter Changes Fuel Filter
New fuel filter. This is the FS2 design. (5 and 10 micron filter-in-filter) fuel filter to retrofit
earlier models (shell and element).
68061633AA FS2 Element, fuel filter and shell.
68061634AA FS2 Element, fuel filter This filter to supersede the original 5183410AA
filter when supplies are exhausted.
6.7-Liter and 5.9-Liter Changes Tank Ventilation
Fuel tank vent hose. 5.9 and 6.7 add-on or upgraded fuel tank vent hose kit with vent cap.
68068997AA Fuel Tank Vent ($66.10). Must be used in conjunction with the appropriate
Fuel Tank Vent Kit listed below:
68051906AA Kit, Severe Duty Fuel Tank Ventilation DC 52 Gallon Tank ($32.95)
68061341AA Kit, Severe Duty Fuel Tank Ventilation D1/DH 35 Gallon Tank ($58.85)
68061342AA Kit, Severe Duty Fuel Tank Ventilation D1/DH 34 Gallon Tank ($63.20)
6.7-Liter and 5.9-Liter Auxiliary Fuel Filter
Severe duty fuel filter kit. This kit supplies the owner with an auxiliary fuel filter, mounting
bracket for under the frame installaiton, hoses, hardware and electrical connections to add
annother fuel filter to the truck.
68083851AA kit, 07-12 Cab and Chassis
68083853AA kit, 04-12 Pickup (2500/3500)
68026934AA wiring adaptor, for use with kit 6808353AA and in the model years 04.5-07
86
CATEGORY 14
FUEL SYSTEM...continued
Editors Comments HD filtration
This is one of those been there, done that TSBs. We discussed the merits of this TSB
and specifically the 6.7-liter and 5.9-liter Auxiliary Fuel filter in last issues magazine,
Issue 77, pages 14-16.
In the cost analysis/conclusion part of the article, I closed by saying, Ding, ding, ding,
bottom line, what is the cost analysis? The Mopar kit will cost about $450. From last
issue, my Fool Transfer Pump/Boy Scout project for the 05 to current trucks cost
$625.
The Fool Transfer Pump/Boy Scout project gives you better filtration and a redundant
pump for fuel supply. However, its installation requires removal of the fuel tank.
Nonetheless, for my peace of mind, Ill spend the $625 and do the extra labor for the fool
solution that I presented in Issue 76. Your decision?
A lot can happen in the 11 months from the beginning of a project to magazine-in-hand.
However, I continue to stand behind my decision to use the redundant FASS Platinum
08-95G fuel transfer pump and filter as I wrote about in Issue 76, pages 16-21.
CATEGORY 18
VEHICLE PEFORMANCE
TSB#
MODEL
SUBJECT/DESCRIPTION
18-004-11
Rev. B
12/21/11
10 (DJ/D2)

This bulletin supersedes service bulletin 18-004-11 Rev. A, dated February 18, 2011. This
bulletin applies to vehicles equipped with a 6.7-liter Cummins engine. The software flash
provides a number of software improvements/enhancements. These include:
P049D EGR control position exceeded learning limit
P2002 Diesel particulate filter efficiency below threshold
P2195 02 sensor 1/1 out of range high
P2196 02 sensor 1/1 out of range low
P2270 02 sensor out of range high
P2271 02 sensor out of range low
P241A 02 sensor 1/1 and oxygen concentration mismatch
P2609 Intake air heater system performance
The previous TSB had software improvements for:
P046C EGR position sensor performance
P0101 Mass air flow sensor A circuit performance
P245B EGR cooler bypass status line intermittent
P2262 Turbocharger boost pressure not detected mechanical
The bulletin involves selectively erasing and reprogramming the engine control module (ECM)
with new software.
87
CATEGORY 18
TSB#
MODEL
SUBJECT/DESCRIPTION
18-045-11
10/19/11
All 6.7-liter dieselequipped vehicles
18-005-12
1/28/12
11 (DD/DP)
Cummins 6.7-liter Turbo Diesel common diagnostic process.

This bulletin supersedes service bulletins 09-002-09 dated June 13, 2009; 09-003-09 dated
December 2, 2009; and 11-001-09 dated July 23, 2009.
This diagnostic process was developed for any drivability concern with the 6.7-liter engine. Nondrivability engine issues or engine cooling system issues are not in the scope of this process.
The process begins by identifying the customers concern and applying it to one of the following
symptoms:
MIL illumination
Engine cranks but does not start or starts and immediately stalls
Engine surges, bucks, runs rough no MIL
Engine noise no MIL
Excessive black smoke out exhaust no MIL
Excessive white smoke out exhaust no MIL
Excessive blue smoke out exhaust no MIL
Once the data has been collected and analyzed, the diagnostic process can continue. The
tests are designed to direct the service technician to the diagnostic path that leads to corrective
actions that repair conditions that occur most frequently for that specific concern.
This bulletin supersedes service bulletin 18-029-11 dated December 17, 2011. Cab chassis
trucks equipped with a 6.7-liter Cummins diesel have a number of software improvements
available. This latest Service bulletin will include:
P0524 Engine oil pressure sensor circuit low
P20EE SCR NOx catalyst efficiency below threshold Bank 1
U010E Lost communication with diesel exhaust fluid control unit
P2609 Intake air heater system performance
P061A ETC level 2 torque performance
P1123 Power take off system monitor control error
P2579 Turbocharger speed sensor circuit performance
Enhanced diagnostics for:
Variable geometry turbocharger
Fuel level sensor
Misfire without MIL illumination
Other updates:
Low diesel exhaust fluid (DEF) level EVIC messaging strategy changes
Diesel Exhaust fluid (DEF) system tampering EVIC messaging strategy changes
Oil change monitor updated for easier reset (same basic procedure, easier to reset)
Scan tool display updates
Enable mobile PTO capability
Correct operation of remote PTO
Correct EVIC messaging related to DEF level reporting
System robustness improvements
DEF tank level reporting erroneously at high DEF tank level. When DEF tank is overfilled, the
EVIC may display low fluid level (20-22%).
with new software.
88
CATEGORY 18
TSB#
MODEL
SUBJECT/DESCRIPTION
18-001-12
Rev A
1/28/12
12 (DD/DP)

This bulletin supersedes service bulletin 18.001/12, dated January 07, 2112. Cab chassis trucks
equipped with a 6.7-liter Cummins diesel have a number of software improvements available.
This latest service bulletin will include:

P061A ETC Level 2 Torque Performance

P20EE ACR NOx Catalyst Efficiency Below Threshold Bank 1

P229F Aftertreatment NOx Sensor Circuit Performance Bank 1 Sensor 2

P2609 Intake Air Heater System Performance

P1123 Power Take Off System Monitor Control Error

U010E Lost Communication With Diesel Exhaust Fluid Control Unit
Enhanced Diagnostics For:

Selective Catalyst Reduction (SCR) efficiency diagnostic improvements.
Other Update:

Idle shutdown message on EVIC.

Turbo protection feature (Not displayed if vehicle is in park or no vehicle speed). Limits
RPM at cold ambient to prevent turbo damage.

Scan tool display updates.

Correct operation of remote PTO.

System robustness improvements.
The bulletin involves selectively erasing and reprogramming the engine control module (ECM)
with new software.
18-013-12
3/17/12
12 (DJ/D2)

This bulletin supersedes service bulletin 18-055-11, dated December 17, 2011. This bulletin
involves selectively erasing and reprogramming the engine control module (ECM) with new
software. The software package has improvements/enhancements available for the following
DTCs:
P049D EGR Control Position Exceeded Learning Limit
P2002 Diesel Particulate Filter Efficiency Below Threshold
P2195 02 Sensor 1/1 Out of Range High
P2196 02 Sensor 1/1 Out of Range Low
P241A 02 Sensor 1/1 and 1/2 Oxygen Concentration Mismatch
Vehicles flashed to address the above codes should be driven and repair validated. If code(s)
return, follow diagnostic procedures available in DealerCONNECT/TechCONNECT.
The software also updates the ECU with other improvements:
Correct water in fuel (WIF) parameter
ScanTool may report a code as stored, even though the fault has been cleared by
completing a significant number of drive cycles without a repeat occurrence.
Active codes not always displayed correctly.
Engine derate with IOD removed. This will help prevent turbo damage due to oil thickening
in cold climate start up on new vehicles in transit.
Scan tool readiness reporting issues.
Other drivability enhancements.
EGR Valve cleaning and monitoring enhancements to help reduce occurrences of P049D.
Erroneous, brief brake lamp flash at key on.
Improve EVIC message regarding idle shut down.
Ability to read EGR valve gap an wiTECH
89
CATEGORY 18
TSB#
MODEL
SUBJECT/DESCRIPTION
18-012-12
3/19/12
11 (DJ/D2)

This bulletin supersedes service bulletin 18-002-11 Rev. B, dated December 16, 2011. This
bulletin involves selectively erasing and reprogramming the engine control module (ECM)
with new software. The new software will have improvements/enhancements available for the
following DTCs:

P0101 Mass Air Flow Sensor A Circuit Performance

P2262 Turbocharger Boost Pressure Not Detected Mechanical
P2457 Exhaust Gas Recirculation Cooling System Performance
P245B EGR Cooler Bypass Status Line Intermittent
P049D EGR Control Position Exceeded Learning Limit
P2002 Diesel Particulate Filter Efficiency Below Threshold (for high altitude failures)
P241A 02 Sensor 1/1 and 1/2 Oxygen Concentration Mismatch
Vehicles flashed to address the above codes should be driven and repair validated. If code(s)
return, follow diagnostic procedures available in DealerCONNECT/TechCONNECT.
The software also updates the ECU with other improvements:
WiTech turbo test revision.
ScanTool may report a code as stored, even though the fault has been cleared by
completing a significant number of drive cycles without a repeat occurrence.
Active codes not always displayed correctly.
Engine derate with IOD removed. This will help prevent turbo damage due to oil
thickening in cold climate start up on new vehicles in transit.
Enhancement to reduce shift clunk at stop.
Other drivability enhancements.
EGR Valve cleaning and monitoring enhancements to help reduce occurrences of
P049D.
CATEGORY 19
TSB#
19-002-12
7/12/12
STEERING
MODEL
SUBJECT/DESCRIPTION
03-04 (DR)
05-09 (DH)
06-09 (D1)
07-09 (DC)
10-12 (D2/DJ/DD)
The customer may experience steering wheel vibration typically while driving above 50 mph.
Vehicles equipped with a solid front axle (4x4 or cab and chassis trucks) can be susceptible
to steering shimmy. Often this condition is due to modifications to the vehicle that may involve
aftermarket equipment that may not be compatible with the vehicle architecture or is not
intended for on-road use. For original equipment, this condition can be corrected with routine
inspection for properly maintained wheels and tires and replacement of damaged or worn
components.
Troubleshooting of the problem begins with the verification of warranty coverage and discussion
with the customer. The technician is directed to test drive the vehicle to confirm the complaint
Next, a long series of inspections, questions, verifications and corrections are presented. The
following gives you an example of how the troubleshooting is done:
Is the vehicle equipped with aftermarket components or other modifications (e.g. lift kits,
wheels, suspension components or tires) that can affect the performance of or wear upon
steering components? If the answer is yes, the dealer is to notify the owner and document
in the repair order that limited warranties do not cover conditions or damage caused by the
use of aftermarket components, improper maintenance, or impact damage can cause steering
shimmy or otherwise accelerate the wear of steering components that cause steering shimmy.
The dealership can inspect steering components that were supplied by the manufacturer for
defects in material, workmanship and factory preparation and determine if necessary repairs are
90
CATEGORY 19
STEERING...continued
covered under the terms of the warranties applicable to the vehicle. Clearly, aftermarket items
may affect who pays for further inspection.

Inspect the vehicle steering components for any damage.

Are the tires on the vehicle properly inflated to the correct pressure?
Do the tires exhibit a condition of excessive wear, cupping or damage?
Verify proper wheel and tire balance.
Inspect the steering damper.
Does the track bar show signs of excessive wear or damage?
Do the tie rods show signs of excessive wear or damage?
Does the drag link show signs of excessive wear or damage?
Verify vehicle wheel alignment is within specification and adjust accordingly.
Do the ball joints show signs of excessive wear or damage?
Editors Comments Death Wobble
If you spend a day answering the tech line at Genos Garage, you would be surprised at
the number of phone calls asking about the Death Wobble.
More often than not, the customer wants a one-size-fits-all answer to the problem. It is
not that easy, and the Genos staff suggests that they save money by crawling under the
truck to diagnose the problem. So, it is refreshing to see that Dodge has helped us tackle
the problem with a step-by-step repair procedure.
The TDR has also covered the death wobble problem and in Issue 74, pages 12-23, we
presented Steering Woes. If you are having death wobble problems, this article is well
worth your reread.
Finally, there is a part not mentioned in the Dodge TSB that can be added to your truck
to help stabilize the front end. My guess as to why Dodge didnt mention a steering box
stabilizer is that it is an aftermarket item not offered through the Mopar parts system.
CATEGORY 21
TRANSMISSION AND TRANSFER CASE
TSB#
MODEL
SUBJECT/DESCRIPTION
21-011-11
11/4/11
11 (DD/DP)
23-006-10
3/10/10
10 (D2/DJ)
Difficulty climbing steep grades at maximum gross combined weight rating in third and fourth
gear.
This bulletin applies to Cab and Chassis vehicles equipped with a six-speed Aisin automatic
transmission. Customers may notice they have difficulty climbing steep grades at maximum
gross combined weight rating while the vehicle is in third and fourth gear. This usually happens
while towing a trailer. This could also be described as a lug down feeling in third and fourth gear.
A new feature has been added to the TCM logic that allows new downshift points for the 4-3 and
3-2 downshifts. These new shift points keep the engine at or near peak horsepower to avoid this
performance issue.
This bulletin involves flash reprogramming the transmission control module (TCM) with new
software.
CATEGORY 23
23-003-12
2/07/12
All Chrysler vehicles
BODY
Hood creaking and squeaking sound.

This bulletin applies to D2/DJ vehicles built before January 29, 2010. The customer may
experience a creaking and/or squeaking sound from the hood area when turning the vehicle
and/or going over rough terrain.
This repair involves adding anti-squeak tape to the hood.
91
CATEGORY 23
BODY...continued
23-019-12
6/19/12
Light to moderate paint surface imperfections on factory applied paint finish.
12 (DJ/DD/D2/
DP)
This information only bulletin applies to vehicles with isolated light to moderate paint surface
imperfections (scratches, bird dropping stains, chemical etching, etc.) on factory applied paint.
The bulletin outlines a list of Meguiars products that can be used to clean the paint.
Service personnel are reminded to always begin with the least aggressive method to remove a
paint condition. Work one section at a time. Always work on a cool paint surface free of bonded
surface contaminants. Should above surface defects be present; prepare the surface with
Meguiars Detailing Clay.
Editors Comments Paint Detailing
When it comes to detailing a truck or car, nothing replaces good lighting, a sharp eye
and lots of elbow-grease.
Again, the TDR and its writers have been there, done that, and the most recent article
on detailing your truck is found in Issue 68, pages 58-65.
Shaking motion in left rearview tow mirror assembly.
This bulletin applies to vehicles built before January 10, 2012. This bulletin involves inspecting
and, if necessary, replacing the left rearview tow mirror assembly.
CATEGORY 25
EMISSIONS CONTROL
TSB#
MODEL
SUBJECT/DESCRIPTION
25-002-11
12/6/11
10-12 (DJ/D2)
On board diagnosis (OBD) monitor readiness.

Vehicles that fail to pass a state mandated emissions inspection may have certain OBD
readiness monitors that have not completely run. Anytime an ECM/PCM has been replaced
or flashed, the OBD readiness monitors may need to run again to complete the monitoring
process. This bulletin describes the necessary steps required to run each monitor.
Customers may be required to drive the vehicle for an extended period of time in a variety of
driving styles to allow all of the OBD monitors to run.
25-003-11
12/6/11
11-12 (DD/DP)
On board diagnosis (OBD) monitor readiness.

Vehicles that fail to pass a state mandated emissions inspection may have certain OBD
readiness monitors that have not completely run. Anytime an ECM/PCM has been replaced
or flashed, the OBD readiness monitors may need to run again to complete the monitoring
process. This bulletin describes the necessary steps required to run each monitor.
Customers may be required to drive the vehicle for an extended period of time in a variety of
driving styles to allow all of the OBD monitors to run.
25-001-12
5/3/12
10-12 (DJ/D2)
11-12 (DD/DP)
Diagnostic trouble code (DTC) P0471 set in temperatures below freezing.

This bulletin involves installing an insulated exhaust manifold pressure (EMP) sensor tube and
insulation over the EMP sensor along with a new EMP sensor.
During the normal combustion process, condensation can form in the EMP sensor tube. Rarely,
this condensation may contact the EMP sensor pressure sensing element. If the vehicle
is operating in temperatures below freezing, the condensation may freeze. The expanding
moisture as it freezes could cause the pressure sensing element to crack causing damage
to the EMP sensor and setting DTC P0471 will illuminate the MIL immediately after the fault
becomes active.
25-003-12
8/02/12
11-12 (DD/DP)
Diesel exhaust fluid.

This bulletin provides information regarding the diesel exhaust fluid (DEF) vehicle delivery
fill guidelines. The bulletin supersedes 25-001-10 dated 9/1/10. The tank is pre-filled with
approximately three gallons of DEF from the manufacturing assembly plant. This factory fill
should be adequate to perform the vehicles Pre-Delivery Inspection and other in-dealership
operations.
92
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 8th VIN Position) built at
the:
Saltillo Assembly Plant (G in the 11th VIN Position) from
March 7, 1997 through May 15, 1997
St. Louis North Assembly Plant (J in the 11th VIN Position)
from March 15, 1997 through May 16, 1997
Lago Alberto Assembly Plant (M in the 11th 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 11th VIN position) through April 4, 1996;
St. Louis (J in the 11th VIN position) through March 23,
1996;
Lago Alberto (M in the 11th VIN position) through April 14,
1996;
Saltillo (G in the 11th VIN position) through April 14, 1996.
The repair involves installing a blower motor relay and overlay
harness to remove the blower motor circuit from the ignition
switch. In addition, the ignition switch and electrical connector
must be inspected for damage and replaced if necessary.
Note to TDR subscribers: the primary parts package for
this repair does not include a replacement ignition switch
assembly, but rather provides a blower motor relay and
overlay harness; if necessary, an ignition switch wiring
pigtail; clips, screws, washers, etc., to install the blower
motor relay.
During the repair the ignition switch and associated
connectors are to be inspected. The technician is instructed
to look for indications of melting or deformation, specifically
at terminals four and five. Very few vehicles are expected to
require ignition switch replacement.
Editors 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 dont jump
to conclusions based on the title of a memo and be sure
additional trailer light wiring and accessories that are added
to your vehicle are on a separate relay-switched circuit.
FUEL TRANSFER PUMP RECALL (878)
The fuel transfer (lift) pump on about 12,000 24-valve
vehicles may be susceptible to premature internal armature
shaft bushing wear. Failure of the shaft bushing typically
causes a no-start condition. To correct the problem, the
supplier of the fuel transfer pump (Federal Mogul) has
returned to the original sintered iron bushing design.
The suspect vehicles have a Cummins engine serial number
sequence that falls between 56662576 and 56671920. These
engines were installed at the DaimlerChrysler assembly
plant in St. Louis from 12/3/99 to 1/18/00; Lago Alberto from
12/2/99 to 2/1/00; Satillo from 12/2/99 to 2/1/00.
The replacement involves removal of the starter motor to
gain access to the electronic transfer pump. Remove and
install a replacement pump. Reinstall the starter and check
for leaks and proper operation. The flat rate time schedule
for replacement is approximately one hour.
THROTTLE CONTROL CABLE AND THROTTLE
LINKAGE REPLACEMENT SAFETY RECALL (970)
DaimlerChrysler Corporation has determined that a defect,
which relates to motor vehicle safety, exists in some 1994
through 1996 model year Dodge Trucks equipped with a
Cummins Turbo Diesel 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 trucks
stopping distance and cause an accident without warning.
DaimlerChrysler will repair your truck free of charge (parts
and labor). To do this, your dealer will replace your trucks
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).
93
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 deformation of the
upper spring plate during assembly of the axle to the vehicle
resulting a soft joint. The soft joint could cause the rear axle
U-bolts to lose clamp load, resulting in displacement of the
rear axle and a loss of vehicle control. This could increase
the risk of a crash. Dealers will remove the spacer plates
and the spring plates will be replaced.
Throttle Cable
(Recall 970)
1994-1996 (BR/BE) Dodge Ram Truck with diesel engine
manufactured from July 1993 to July 1996.
On certain pickup trucks, the throttle cable could unravel
(fray) or break, resulting in a loss of throttle control. A throttle
that does not return to idle could result in unexpected
acceleration, increasing the risk of a crash. Dealers will
inspect and replace the throttle cable and upper bell crank
lever.
Brake Hose/ABS Sensor Wire
Assembly Clearance
(Recall 971)
2000 (BR/BE) Dodge Ram Truck with ABS 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 the ABS sensor wire will be inspected and
replaced if necessary.
94
Clockspring
(Recall 982)
2001 (BR/BE) Dodge Ram Truck manufactured from May
2000 To October 2000.
Sound deadener material internal to the clockspring could
become detached from the clockspring cover and housing.
When this occurs, the material could interfere with the
clockspring ribbon and cause an open circuit. The driver air
bag system will become disabled and the air bag warning
lamp will illuminate on the instrument panel. Dealers will
replace the clockspring assembly.
Customer Satisfaction Notification No. C44
Transmission Cooler Line
Date: February 2004
Models: 03-04 (DR)
This notification applies only to trucks equipped with a 5.9
liter Cummins diesel engine (sales code ETC or ETH) and
an automatic transmission (sales code DG8 or DGP) built
through November 24, 2003. The transmission cooler line
on about 97,000 of the above vehicles can transmit high
pressure pulses when the vehicle is operated at heavy loads.
These pulses may cause the engine-mounted transmission
cooler to crack and leak fluid which could result in significant
transmission damage.
Repair: The transmission cooler line must be replaced
on all involved vehicles. In addition, the engine-mounted
transmission cooler must be inspected and replaced if
necessary.
Customer Satisfaction Notification No. C42
Powertrain Control Module Connectors
Date: February 2004
Models: 03 (DR)
This notification applies only to trucks equipped with a 5.9
liter Cummins diesel engine (sales code ETC or ETH) and
an automatic transmission (sales code DGP or DG8) built
through July 9, 2003. The Powertrain Control Module (PCM)
electrical connectors on about 70,000 of the above trucks
may allow water to enter into the connectors. Water and the
resulting corrosion in a PCM connector can cause the speed
control and/or transmission overdrive function to become
inoperative.
Repair: The three electrical connectors on the PCM must
be removed and inspected for corrosion. If no corrosion is
found, the connectors must be sealed by installing rubber
O-rings onto the harness connectors.
If corrosion is found in the connector, the transmission wiring
harness and PCM must be replaced.
CUSTOMER SATISFACTION NOTIFICATION E10

FRONT SUSPENSION COIL SPRINGS
Date: July 2005
Models: 05 (DH) Dodge Ram 3500 4x2 Pickup Truck
This notification applies only to the above vehicles built
through May 27, 2005. Incorrect front coil springs may have
been installed on about 8,100 of the above trucks front
suspension. This may cause the front suspension to bottom
out prematurely, which can reduce ride quality.
Repair: Both front suspension coil springs must be replaced.
SAFETY RECALL E17
OUT-OF-PARK ALARM SYSTEM
Date: March 2006
Models: 03 04 (DR)
05 (DH)
This recall applies only to the vehicles equipped with a 5.9L
diesel engine (6 or C in the eighth VIN Position) and an
automatic transmission (sales code DGP or DG8). In certain
circumstances when a driver has not placed the shifter
lever fully into the Park position and leaves the engine
running, the vehicle may unexpectedly move rearward after
seeming to be stable. Unintended rearward movement of a
vehicle could injure those in and/or near the vehicle.
Repair: An Out-of-Park alarm system must be installed on
the vehicle. The alarm system will beep the horn and flash
the headlamps and shift indicator if a driver tries to exit
a running vehicle without fully placing the shifter into the
Park position.
SAFETY RECALL F05
ANTILOCK BRAKE SYSTEM CONTROL MODULE
Date: July 2006
Models: 06 (D1) Dodge Ram Pickup (3500 Series)
06 (DH) Dodge Ram Pickup (1500 Mega Cab
and 2500 Series)
This recall applies only to the above vehicles equipped
with a four-wheel Antilock Brake System (sales code BGK
or BRT) built from September 12, 2005 through December
11, 2005. The Antilock Brake System (ABS) control module
on about 37,900 of the above vehicles may cause the rear
brakes to lock up during certain braking conditions. This
could result in a loss of vehicle control and cause a crash
without warning.
Repair: The ABS control module must be replaced and
initialized with the StarSCAN tool.
CUSTOMER SATISFACTION NOTIFICATION F19

ROLL-OVER VALVE VENT HOSES
Date: June 2006
Models: 06 (DH) Dodge Ram 2500 Pickup and Cab-Chassis
06 (D1) Dodge Ram 3500 Pickup and Cab-Chassis
This notification applies only to the above vehicles equipped
with a 5.9L diesel engine (C in the eighth VIN position) built
through February 1, 2006. The roll-over valves on about
69,300 of the vehicles may allow water to enter into the fuel
tank. Excessive water in the fuel can damage the injection
pump and/or injectors if the engine is off for an extended
period of time.
Repair: A vent hose must be installed at each tank rollover valve (ROV). The fuel system must be inspected for
excessive water content. If excessive water is found, the
water must be removed and the fuel filter must be replaced.
EMISSIONS RECALL G30
REPLACE OXYGEN SENSOR MODULE
AND REPROGRAM ECM
Date: October 2007
Models: 07 08 (DH/D1) Dodge Ram 2500/3500 Pickup
Truck
with a 6.7-liter diesel engine built through August 20, 2007.
The on-board diagnostic (OBD) system on about 74,000 of
the above vehicles may not detect a failed oxygen sensor or
illuminate the malfunction indicator light (MIL) as required.
In addition, the OBD system may cause these trucks to fail
an inspection maintenance test and may not store mileage
as required for certain transmission faults.
Repair: The oxygen sensor module must be replaced and
the engine control module (ECM) must be reprogrammed
(flashed). The new software will also improve vehicle
drivability and reduce the potential for exhaust soot
accumulation in the vehicles particulate filter. The
recalibration of the ECM updates and supersedes TSB 18033-07 Revision B, dated 6/28/07 (see page 63 for details).
EMISSIONS RECALL H31
VECI LABEL
Date: October 2008
Models: 08 (D1) Dodge Ram 3500 Truck Cab and
Chassis
An incorrect Vehicle Emission Control Information (VECI)
label was inadvertently installed on about 60 of the above
vehicles. The original VECI label does not include the
required information for vehicles built without a pickup box.
Repair: A new VECI label must be installed over the
vehicles original VECI label.
95
SAFETY RECALL H34

DASH SILENCER PAD
Date: January 2009
Models: 07 08 (DH, D1, DC, DM)
The dash silencer pad on about 110,000 vehicles, built with
a Cummins 6.7-liter diesel engine through 11/5/07, may sag
and contact the exhaust gas recirculation (EGR) cooler.
This may cause the dash silencer to locally overheat and
cause an underhood fire without warning.
Repair: All vehicles must have a dash silencer pad support
bracket installed.
SAFETY RECALL H36

STEERING DRAG LINK INNER JOINT
AND DAMPER BRACKET
Date: May 2009
Models: 08 09 (DH/D1) 2500/3500 series or 1500 Mega
Cab (4x4 only)

08 09 (DC) 3500 series Cab Chassis
This recall applies only to the above vehicles built from
February 19, 2008 through October 30, 2008.
The steering drag link inner joint on about 32,700 of
the above vehicles may fracture under certain driving
conditions. This could result in a loss of steering control and
cause a crash without warning.
Repair: The steering linkage must be inspected and some

steering linkage components may need to be replaced.
CALIFORNIA EMISSIONS RECALL K01

REPROGRAM ECMOBD READINESS
Date: May 2010
Models: 03 (DR) Dodge Ram 2500/3500 Pickup Truck

06-07 (DH/D1) Dodge Ram 2500/3500 Pickup
Truck

07 (DC) Dodge Ram 3500 Cab Chassis
This recall applies only to the above vehicles equipped with
a 5.9-liter diesel engine (sales codes ETC and ETH) and a
California emission control system (sales code NAE). And
to above vehicles equipped with a 6.7-liter diesel engine
(sales code ETJ) and a California emission control system
(sales code NAE) built through January 5, 2007.
The Engine Control Module (ECM) on the above vehicles
may fail to accurately report diagnostic system information
with some generic scan tools This may cause the vehicle
to be rejected or fail an Inspection/Maintenance Test (also
known as a Smog Check).
Repair: The Engine control Module (ECM) must be
reprogrammed (flashed).
Also the steering damper bracket at the tie rod tube may
loosen. This could allow the bracket to slide on the tube and
may cause increased vehicle turning radius.
EMISSIONS RECALL J35

REPROGRAM ECMREGENERATION STRATEGY
Repair: The drag link inner joint must be replaced and the
steering damper bracket must be inspected and replaced,
if required.
Date: April 2010

Models: 07.5-09 (DH/D1) Dodge Ram 2500/3500 Pickup
Truck
SAFETY RECALL H46

MOPAR STEERING LINKAGE
Date: May 2009
Models: 03 04 (DR) 2500/3500 series 4x4

05 (DH) 2500/3500 series 4x4

06 09 (DH) 2500/3500 series or 1500 Mega
Cab 4x4

06 09 (D1) 3500 series 4x4

07 09 (DC) 3500 series Cab Chassis
This recall only applies to vehicles that had certain Mopar
service parts steering components installed.
During a prior service appointment, a Mopar service parts
steering linkage was installed on about 13,900 of the above
vehicles. The drag link inner joint may fracture under certain
driving conditions. This could result in a loss of steering
control and cause a crash without warning.
96
Also, the steering damper bracket at the tie rod tube may
loosen. This could allow the bracket to slide on the tube and
may cause increased vehicle turning radius.

with a 6.7-liter diesel engine (sale code ETJ). The Engine
Control Module (ECM) software program on the above
vehicles may cause illumination of the Malfunction Indicator
Lamp (MIL) when no problem exists or under certain
conditions allow heavy sooting of the turbocharger, exhaust
gas recirculation valve and diesel particulate filter. Heavy
sooting could damage emissions components and result in
increased emissions.
Repair: The Engine Control Module must be reprogrammed
(flashed). The bulletin describes the service procedure that
the dealership technician is to follow. Using the dealerships
scan tools, the time allowance for the reprogramming
operation is less than one hour. As a part of the recall and
ECM update the technician has to verify that the previous
emissions recall, recall G30, October 2007, has been
performed. The G30 recall contains software that must be
installed to prevent damage to the ECM. There are no parts
involved in the J35 recall notice.
SAFETY RECALL K08

WIRELESS IGNITION NODE RECEIVER
SAFETY RECALL K28

LEFT TIE ROD END
Date: August 2010

Models: 10 (DJ) Ram Truck (2500 Series)

10 (D2) Ram Truck (3500 Series)
This recall applies only to the above vehicles built at Saltillo
Assembly Plant (G in the 11th VIN position) equipped with
an automatic transmission from January 6, 2010 through
February 16, 2010. This recall also affected other Chrysler
vehicles.
Date: February 2011

Models: 08-10 (DM) Ram Truck
(4500/5500 series cab chassis)

11 (DP) Ram Truck
(4500/5500 series cab chassis)
This recall applies only to the above vehicles built through
September 02, 2010.
The Wireless Ignition Node (WIN) receiver on about 8,900

of the above vehicles may experience a condition where
the Frequency Operated Button Integrated Key (FOBIK)
may be removed prior to placing the automatic transmission
gear shift lever in the PARK position. This could result in
unintended vehicle movement and cause a crash without
warning.
To correct this condition, the Wireless Ignition Node receiver
must be inspected and replaced if necessary. The new WIN
must be programmed and all FOBIK transponders must be
programmed so they are able to interface with the new WIN
receiver.
CUSTOMER SATISFACTION NOTIFICATION K17

REPROGRAM HVAC CONTROL HEAD AND
INSPECT/REPLACE ACTUATORS
Date: September 29, 2010
Models: 10 (DJ) Ram Truck (2500 series)

10 (D2) Ram Truck (3500 series)
This recall applies only to the above vehicles built through
May 22, 2010
The HVAC mode door actuator gears on about 52,000 of
the above vehicles may break and result in the inability to
fully control the HVAC functions.
To correct this condition, all involved vehicles must have
updated HVAC control head software installed and the
mode door actuators must be tested and replaced as
required.
The left outer tie rod end on about 15,500 of the above
vehicles may fracture due to a misalignment condition.
Under certain driving conditions, this may lead to a
weakening and eventual fracture of the left outer tie rod ball
stud. A fractured tie rod end could cause a loss of directional
stability and a crash without warning.
The left outer tie rod end must be replaced, toe-in must be
set, and the tie rod ends must be aligned.
CUSTOMER SATISFACTION NOTIFICATION L14
REPROGRAM HVAC CONTROL HEAD
Date: April 12, 2011
Models: 10 (D2) Ram Truck (2500 series)

10 (DJ) Ram Truck (3500 series)
This notification applies only to the above vehicles built with
Manual Temperature Control (MTC) from March 18, 2010,
through June 24, 2010.
The Heating, Ventilation, and Air Conditioning (HVAC)
control head software on about 10,330 of the above
vehicles may cause the mode door actuator gears to make
noise and/or break. This could cause the inability to fully
control the HVAC functions.
To correct this condition, the HVAC control head must be
reprogrammed with new software.
SAFETY RECALL K33
POWER STEERING RESERVOIR CAP
Date: February 1, 2011
Models: 10-11 (DC/DM/DJ/D2/DD/DP) Ram Truck
This recall applies only to the above vehicles equipped with
a Cummins engine built at the Saltillo Assembly Plant (G
in the 11th VIN Position) through October 05, 2010.
The power steering reservoir cap on about 11,300 of the
above vehicles may cause excessive vent pressure levels
in the power steering/hydraulic brake booster system. This
may cause the vehicle to have brake lights that remain
illuminated for an extended period of time after the brake
pedal has been released. Brake lights that are slow to turn
off could increase the risk of a crash.
To correct this condition, the power steering reservoir cap
must be replaced.
97
EMISSIONS RECALL K34

REPROGRAM ECM EGR DIAGNOSTIC
Date: February 8, 2011
Models: 10 (DJ/D2) Ram Truck (2500/3500 series pickup)
with a Cummins engine built from October 1, 2009, through
June 24, 2010.
The Engine Control Module (ECM) on about 1193 of the
above vehicles may have been built with a software error
that prevents the EGR cooler bypass valve diagnostic from
running after detecting a pending fault, disabling deNOx
without illuminating the MIL. This may cause the vehicles
exhaust emissions to exceed the allowable limit for oxides
of nitrogen.
To correct this condition, the Engine Control Module (ECM)
must be reprogrammed (flashed).
CUSTOMER SATISFACTION NOTIFICATION L03
DOOR LATCHES
Date: March 2011
Models: 11 (D2) Ram Truck (3500 Series) Pick up

11 (DD) Ram Truck (3500 Series) Cab Chassis

11 (DJ) Ram Truck (2500 Series) Pick up

11 (DP) Ram Truck (4500/5500 Series) Cab
Chassis
with power door locks (sales code JPB) built from July 01,
2010, through November 23, 2010.
The right front door latch, right rear door latch and/or swing
gate latch on about 35,000 of the above vehicles may
develop a ratcheting sound while using the power door
locks.
The right front door latch and right rear door latch must be
inspected and replaced if necessary.
SAFETY RECALL L16
LEFT TIE ROD
Date: March 2012
Models/Production:

08-09 (DH) 2500 (4x4)

08-09 (D1) 3500 (4x4)

10-11 (DJ) 2500 (4x4)

10-11 (D2) 3500 (4x4)

08-10 (DC) 3500 Cab Chassis

11 (DD) 3500 Cab Chassis
This recall applies only to the above vehicles built at the
February 14, 2008, through March 28, 2011.
Models/Service Parts:

03-04 (DR) 2500/3500 (4x4)

06-08 (D1) 3500 (4x4)


05-08 (DH) 2500 (4x4)

05 (DH) 3500 (4x4)
98
This recall applies only to the above vehicles that were built
between July 12, 2002, and February 13, 2011, and had
the steering linkage replaced with Mopar service parts after
February 14, 2008.
Subject: The left tie rod ball stud on about 208,000 of
conditions. This could cause a loss of directional control
and/or a crash without warning.
The same vehicles may also have a loose front track bar
bolt. This could cause a rattle or banging noise under
certain driving conditions.
Repair: The vehicle must be inspected for the type of
steering linkage the vehicle is equipped with and those
found with a certain linkage configuration must have the
right and left tie rod angles measured. If the tie rod angles
are not within specification, the left tie rod must be replaced.
Note: special Tool 10326 was released to dealers in
November of 2010. Service Bulletin 19-001-11 was also
issued to alert dealers to the new service tool and procedure
for setting toe on the affected, and all subsequent, vehicles.
Conclusion
If Ive heard it once Ive heard it a hundred timesthe
TDR reads like a storybook and you have to keep the back
issues handy or youll miss a topic that has been previously
covered.
At times I know it is frustrating. But, for the sake of the
editors sanity and page count containment, I often do the
chapter-and-verse thing. The point of this rambling: if you
have a problem with a late model truck youll want to review
the TSBs in issues 74, 70, 66 and 62, all of which can be
found at our web site.
Likewise, review those magazines for any recall notices
that may apply to you.
Is the grass greener on the other side? We hope the TSB
and Recall information will help you in your purchase/
ownership of the Dodge Cummins Turbo Diesel truck. We
choose to think that answers and solutions are much better
than wonderment. Happy Motoring!
Finally, did you notice that the TSBs are fewer in number
at the end of a vehicles lifecycle? What is an owner to do,
purchase the end of the old generation on be the first-onthe-block with the new? Both scenarios have their benefits.
Regardless of you choice, Ill try to keep you up to date with
our annual TSB review.
Robert Patton
TDR Staff
Recall Notices, 2012

SAFETY RECALL L16
LEFT TIE ROD
Date: March 2012
Models/Production:

08-09 (DH) 2500 (4x4)

08-09 (D1) 3500 (4x4)

10-11 (DJ) 2500 (4x4)

10-11 (D2) 3500 (4x4)


11 (DD) 3500 Cab Chassis
This recall applies only to the above vehicles built at the
February 14, 2008, through March 28, 2011.
Models/Service Parts:

03-04 (DR) 2500/3500 (4x4)

06-08 (D1) 3500 (4x4)


05-08 (DH) 2500 (4x4)

05 (DH) 3500 (4x4)
This recall applies only to the above vehicles that were built
between July 12, 2002, and February 13, 2011, and had
the steering linkage replaced with Mopar service parts after
February 14, 2008.
Subject: The left tie rod ball stud on about 208,000 of
conditions. This could cause a loss of directional control
and/or a crash without warning.
Conclusion
If Ive heard it once Ive heard it a hundred timesthe
TDR reads like a storybook and you have to keep the back
issues handy or youll miss a topic that has been previously
covered.
At times I know it is frustrating. But, for the sake of the
editors sanity and page count containment, I often do the
chapter-and-verse thing. The point of this rambling: if you
have a problem with a late model truck youll want to review
the TSBs in issues 74, 70, 66 and 62, all of which can be
found at our web site.
Likewise, review those magazines for any recall notices
that may apply to you.
Finally, did you notice that the TSBs are fewer in number
at the end of a vehicles lifecycle? What is an owner to do,
purchase the end of the old generation on be the first-onthe-block with the new? Both scenarios have their benefits.
Regardless of you choice, Ill try to keep you up to date with
our annual TSB review.
Robert Patton
TDR Staff
The same vehicles may also have a loose front track bar
bolt. This could cause a rattle or banging noise under
certain driving conditions.
Repair: The vehicle must be inspected for the type of
steering linkage the vehicle is equipped with and those
found with a certain linkage configuration must have the
right and left tie rod angles measured. If the tie rod angles
are not within specification, the left tie rod must be replaced.
Note: special Tool 10326 was released to dealers in
November of 2010. Service Bulletin 19-001-11 was also
issued to alert dealers to the new service tool and procedure
for setting toe on the affected, and all subsequent, vehicles.
99

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TECHNICAL

A Publication of the Turbo Diesel Register

Over the Years

A Publication of the TURBO DIESEL REGISTER

TSBs Issued During 1989-1995

Rattling/clunk type noise from front of vehicle.

Service manual revisions for torque values on front suspension.

Low ride height on 8800 GVW cab chassis.

Service manual revision for torque values on stabilizer link bar.

Front spring spacer for two wheel drive trucks.

02-06-90A 90 - 91 (AD) 2WD

Front spring spacer for two wheel drive trucks.

Service manual revision for camber specification.

Rear axle trac-loc chatter.

A Publication of the TURBO DIESEL REGISTER

Drift left or right under moderate or hard braking.

Front brake noise on trucks with 86 mm diameter caliper pistons.

Premature brake wear on trucks with 12 brake drums.

Brake pedal noise.

Premature brake wear on trucks with 12 brake drums.

Rear wheel anti-lock speed sensor connector repair procedure.

Front disc brake noise from Bendix disc brakes.

Rear wheel anti-lock faults caused by water contamination.

Transmission noise below 1400 rpm.

A Publication of the TURBO DIESEL REGISTER

Service manual revision - thermostat seals.

Engine slow to warm-up in cold ambient temperatures.

Overheating or no heat condition.

Lower radiator hose leakage.

Fan belt noise/chirp.

Recycled engine coolant.

Auxiliary oil cooler freeze-up.

Power mirror vibration associated with installation of bugscreen deflectors.

Accessory frame ground jumper wire.

A Publication of the TURBO DIESEL REGISTER

Installation of radio equipment.

Speed control - over/undershoot during set of speed selection.

Poor AM radio reception.

Infinity radio (code RAY) looses sound on right channel speakers.

Weak sounding horn.

Fuel gauge sticks.

Battery drain on vehicles equipped with trailer tow package.

Diesel secondary battery does not chargevehicles built prior to 2/14/94.

Fuel gauge inaccuracy.

Trailer tow brake wire location.

Power mirror vibration.

Poor AM radio reception.

White smoke at start-up.

Speed control surge.

A Publication of the TURBO DIESEL REGISTER

Erratic coolant temperature gauge reading.

Fuel gauge innaccuracy.

Service procedure for the stop light switch connector.

Trailer tow wiring installation.

Speedometer reading fluctuates and/or the speed control disengages.

Fuel reads low when fuel tank is full.

Diagnosing oil consumption.

Excessive oil drainage from oil draft (breather) tube.