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Buyer`s Guide - Turbo Diesel Register

1. a Boost Model Year HP RPM Torque RPM CPL Transmission Comments Specification 89 91 160 2500 400 1600 804 Auto Manual 22 25 91 5 92 160 2500 400 1600 1351 Auto Manual Mid year intercooler 15 19 92 5 93 160 2500 400 1600 1579 Auto Manual Mid year change 15 19 94 160 2500 400 1600 1815 Auto 15 18 12 Valve 175 2500 420 1600 1816 Manual 15 18 94 5 160 2500 400 1600 1549 Auto Mid year catalyst 15 18 12 Valve 175 2500 420 1600 1550 Manual Mid year catalyst 15 18 95 160 2500 400 1600 1959 Auto 15 18 12 Valve 175 2500 420 1600 1550 Manual 15 18 A Publication of the TURBO DIESEL REGISTER Boost Model Year HP RPM Torque RPM CPL Transmission Comments Specification 95 5 160 2500 400 1600 1968 Auto mid year change 15 18 12 Valve 175 2500 420 1600 1550 Manual mid year change 15 18 180 2500 420 1600 2022 Auto EPA 19 a Weis 215 2600 440 1600 2023 Manual EPA 25 180 2500 420 1600 1863 Auto Manual CARB Catalystand EGR 19 180 2500 420 1600 2174 Auto EPA 19 ae 215 2600 440 1600 2175 Manual EPA 25 180 2500 420 1600 2308 Auto Manual CARB Catalystand EGR 19 2098 2513 Auto EPA 18 215 2700 420 1600 98 5 2280 2515 Auto CARB 18 24 Valve 2024 2512 Manual EPA
2. 95 BR trucks with a build date prior to 1 1 95 94 BR 4x4 94 BR 89 93 AD 89 91 AD with four wheel drive CATEGORY 21 SUBJECT DESCRIPTION Clunk or rattle felt in steering wheel column over rough surfaces or while making a turn The repair involves performing an inspection of suspension and steering components to assure proper torque The replacement of the steering column intermediate shaft is described Slow steering return The bulletin applies to 4x4 trucks with a Dana 60 axle The diagnosis involves using a spring scale to determine turning force The repair involves performing a ball joint tightening Low power assist in cold ambient temperatures The condition can be minimized by reviewing the cold start procedures steering fluid pn 04778524 may be used Cold climate power Steering Column coupler A repair package with a revised boot has been developed to service the steering coupler The part number is 4740761 This is an information only bulletin Steering wheel off center Due to a shift in the steering gear bracket in high load conditions the steering wheel may be off center during straight driving The repair involves installing a shoulder bolt that acts as a dowel pin locking the steering gear bracket to the frame TRANSMISSION TSB 21 02 95 3 31 95 21 03 95 A 6 16 95 21 04 95 4 14 95 21 05 95 A 1 5 96 21 08 95 1 30 95 21 09 95 6 30 95
3. Maximum Tow Ratings 2500 regular cab extended cab quad cab manual 4x2 3 54 or 4 10 axle 20 000 GCWR Except 12 valve California trucks 3 54 axle is 16 000 4 10 axle is 18 000 GCWR 2500 regular cab extended cab quad cab automatic 4x2 and all 4x4 models 3 54 axle 16 000 GVWR 4 10 axle 18 000 GVWR 3500 regular cab manual 4x2 3 54 or 4 10 axle is 20 000 GVWR 3500 extended cab quad cab manual 4x2 and 4x4 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR 3500 extended cab quad cab automatic 4x2 and 4x4 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR Cab Chassis models Available in regular cab only 2500 is 8 800 GVWR 56 C A cab to axle dimension 3500 is 11 000 GVWR and available in 60 and 84 C A dimensions 2500 and 3500 manual have 20 000 pound tow rating with either axle in 4x2 and 4x4 2500 and 3500 automatic 4x2 and 4x4 have 16 000 GCWR with 3 54 axle and 18 000 GCWR with 4 10 axle Comments Watch tow ratings carefully Mid year introduction of the 24 valve engine for cleaner emissions Early problems with failed fuel lift pumps and locked up injection pumps Owners find out that a 4 10 1 axle ratio is better for towing with the 24 valve engine since the power band has been moved higher in the RPM range 24 valve engine governed RPM is raised to 3 200 Electronically controlled fuel injection produces a flat torque curve from 1700 2700 RPM In November of 98 Dodge issues a bulletin to al
4. Pinch the outer tangs of the fuel line quick fitting Do not forget to remove the old O ring An O ring on top of to separate the rubber hose from the hard fuel line an O ring doesn t work too well Ask me how I know A Publication of the TURBO DIESEL REGISTER 119 120 e Assemble the new components to match the routing of the existing fuel pump and fuel line With the old transfer pump and fuel line removed you can see the orientation of the new fuel lines and primary fuel filter e Install the new O ring to the fuel pump Install the fuel pump into the filter housing Position the fuel pump and push into place e Install the four 5mm hex head bolts 61 inch Ibs e Connect the electrical connector to the fuel pump e Back under the truck Check to be sure that the orientation of the new fuel line matches the route of the fuel line that was removed Snap the fuel line quick connect onto its fitting The installed orientation of the new fuel filter e Do a double check of your work It is time to start the truck Bump the starter but do not attempt a complete start cycle Return the key to the run position and listen for the fuel pump to operate it will cycle for 15 20 seconds Repeat the bump return to run technique for 4 5 cycles to be sure that air has been purged out of the engine s self priming fuel system e Crank the truck and check for leaks You re finished am pleased to report the success of this
5. TSB MODELS SUBJECT DESCRIPTION 02 003 08 08 DM Front and or rear shock absorber noise 6 20 08 4500 5500 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 40 F and at lower vehicle speeds when background noise is less The sound may come from the front and or rear shock absorbers This condition is due to internal components within the vehicle shock absorber and the bulletin describes the replacement procedure A Publication of the TURBO DIESEL REGISTER 15 TSBs Issued During 03 07 CATEGORY 3 AXLE DRIVELINE TSB MODELS SUBJECT DESCRIPTION 03 003 04 03 04 DR Launch shudder 6 15 04 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 nece
6. 99 3931476 3937145 3097074 5080810 oe FS19598 LF3059 LF3894 AF25541 04883963AB 05016547AB 4728406 eo a 3931476 3937145 3097074 5080810 ee g FS19598 LF3959 LF3894 AF25541 A Publication of the TURBO DIESEL REGISTER 139 1998 04883963AB 05016547AA 4728406 71715 Avaive endive 3931476 3932217 3865405 3097074 5080810 71716 g FS19598 LF3349 LF3552 AF25541 04883963AB 05016547AA 4728406 97 3931476 3932217 3865405 3097074 5080810 71715 FS19598 LF3349 LF3552 AF25541 71716 4741689 05016547AA 4728406 71715 96 3923108 3932217 3865405 3097074 5080810 71716 FS1253 LF3349 LF3552 AF25541 4741689 05016547AA 4728406 71715 95 3923108 3932217 3865405 3097074 5080810 71716 FS1253 LF3349 LF3552 AF25541 4741689 05016547AA 4728406 71715 94 3923108 3932217 3865405 3097074 5080810 71716 FS1253 LF3349 LF3552 AF25541 4429107 05016547AA 4713953 71594 93 3834656 3932217 3865405 3097073 5080830 71595 FS1232 LF3349 LF3552 AF25023 4429107 05016547AA 4428308 71594 92 3834656 3932217 3865405 3097072 5080830 71595 FS1232 LF3349 LF3552 AF4555M 4429107 05016547AA 4428308 71594 91 5 3834656 3932217 3865405 3097072 5080830 71595 FS1232 LF3349 LF3552 AF4555M 4429107 05016547AA 4428308 70540 91 3834656 3932217 3865405 3097072 5080820 71530 FS1232 LF3349 LF3552 AF4555M 4429107 05016547AA 4428308 70540 90 3834656 3932217 3865405 3097072 5080820 71530 FS1232 LF3349 LF355
7. MODELS 95 BR built after 3 20 95 94 95 BR 94 95 BR trucks with automatic transmission 94 95 BR trucks with automatic transmission 94 95 BR 94 95 BR trucks with manual transmission SUBJECT DESCRIPTION Quick connect removal and reconnect procedure The bulletin is an information only bulletin outlining two ways to disconnect the quick connectors of the automatic transmission lines Automatic transmission cold temperature cooler bypass kit The condition occurs at ambient temperatures of 15 F or below Vehicles equipped with automatic transmission coolers may experience a lack of fluid flow to the transmission due to restricted cooler lines In periods of extended driving transmission failure may result The bulletin describes the installation of a cold weather transmission cooler by pass kit Caution is needed as the kit decreases the cooling capacity of the transmission when driving in hot ambient temperatures and is not recommended Vibration or perceived engine miss The symtom is a vibration or perceived engine miss at approximately 1100 rpm as the torque converter clutch engages The condition occurs in fourth gear lock up at speeds between 42 to 48 mph Depending on year model the powertrain control module is either replaced or reprogramed Delayed transmission engagement torque convertor drainback The condition is delayed transmission engagement of
8. The bulletin applies to vehicles built before 10 28 93 and involves the replacement of the throttle control lever to ensure full throttle travel Also adjustment of the throttle position sensor is described Excessive White Smoke Low Power The bulletin involves a diagnostic check of the cooling system and starting instructions before verifying timing of the engine Manual transmission engines are set to 12 5 degrees top dead center Automatic engines should be set according to the engine data plate Poor performance lack of power The bulletin discusses the troubleshooting procedures for a poor performance complaint After verification of engine system performance the bulletin outlines the criteria for a torque converter stall test for automatic equipped trucks and a 20 50 mph test for manual transmission trucks An adjustment procedure for the LDA a timing advance that is controlled by boost pressure is described The bulletin is known as the starwheel or balloon test by service technicians Erratic 3 4 or 4 3 shifts The bulletin discusses erratic shifting hunting between third and fourth gear The shift schedule is based on several inputs to the powertrain control module SEBC Diagnosis of the components is described If a throttle position sensor is required the replacement part number is 4746966 Vehicle surging when cruise control is engaged The condition may be caused by the calibration of the powertrain control mod
9. kid 7e fe ce fe A Publication of the Turbo Diesel Register A WORD ABOUT THE TURBO DIESEL REGISTER How did the Turbo Diesel Register get its start First off I m an automotive enthusiast An automotive enthusiast that was in search of a tow vehicle for my admittedly small collection of automobiles As you can imagine the search for the right tow vehicle took me in the direction of the Dodge Cummins Turbo Diesel My search was aided by the fact that my previous job was in the diesel engine profession as a Cummins distributor product support representative Do have a good knowledge of the Turbo Diesel engine Well maybe l II let you be the judge Back to the story As an automotive enthusiast am a member of a handful of car club register type publications In addition subscribe to just about every car and truck monthly publication in hopes that can learn something more about my vehicles The only vehicle owned that didn t have its own club was the Turbo Diesel The light goes on Why not start a Turbo Diesel club The light flickers know the immediate answer not enough time no money and who would write the articles Needless to say the idea got put on the back burner Another great idea but Looking back that was many long years ago Prior to our first magazine Fall 93 took time to talk to other Turbo Diesel owners who wanted to know more about their truck and specifically
10. 15 1996 If the driver s side wiper blade contacts A Pillar or a popping sound can be heard when the driver s side wiper blade reaches its full upper wipe position farthest to the left during high speed wiper operation this bulletin describes the repair procedure The repair has the dealership replace the wiper blades with a blade that has a revised air deflector 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 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 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 driver s side mirror 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 bo
11. MODELS SUBJECT DESCRIPTION 08 09 98 94 98 BR Driver side power mirror vibrates while driving 3 13 98 This bulletin supersedes technical service bulletin 23 39 97 dated June 27 1997 The problem covered is that the driver side power mirror vibrates or causes blurred images in driver side mirror while driving If removal of aftermarket bugscreen deflectors does not cure the problem a procedure for installing a mirror reinforcement bracket is described 08 11 98 98 BR Delayed operation of fog lamps 3 13 98 The fog lamps illuminate approximately two seconds after being turned ON with the headlamp LOW beams illuminated This condition may also occur when the headlamps are turned from HIGH beam to LOW beam with the fog lamps ON The repair involves checking the headlamp connector for proper wire location 08 13 98 98 BR Headlamp switch knob pulls out of headlamp switch 3 27 98 This bulletin applies to vehicles built before November 16 1997 Rotate the headlamp switch knob to the full dim position Then apply pressure to the side of the knob and pull the knob to turn the headlamps ON If the knob pulls out of the headlamp switch when the headlamps are turned ON replace the knob using the described repair procedure 6 A Publication of the TURBO DIESEL REGISTER CATEGORY 8 ELECTRICAL Continued 08 14 98 3 27 98 08 16 98 4 17 98 08 17 98 Rev C 12 30 98 08 21 98 5 22 98 08 35 98 6 24 98 08 36 98 6
12. for corrosion The downshift is made when the failed TTS sensor says the outside temp is below 5 zero volts The upshift is made when the TTS again sends a signal 1 to 5 volts to the PCM saying the outside temp suddenly climbed to ambient temp thus allowing overdrive to be engaged Ref 37 p 46 A Publication of the TURBO DIESEL REGISTER Glitch 89 91 5 truck runs hot Fix This version of the engine was turbocharged but not intercooled and long uphill climbs at full throttle caused the engine to overheat due to hot turbocharged air particularly if the fueling had been turned up for more power Members routed a fresh air duct from the front of the truck to the turbocharger area to cool the turbo thus cutting the heat load on the engine and the aftermarket developed intercoolers that usually came with a new grille for clearance Another solution to the 89 to 91 run hot problem was the retrofit of the larger radiator and fan used in the 91 5 to 93 trucks Way back in Issue 6 TDR member Bruce Burney presented four pages of step by step instructions as well as a detailed parts list approximately 750 in 1991 to do the conversion From pictures in our archives the 91 593 radiator looks to be about half again as large Should a member need a reprint we will be happy to fax the article to him SECOND GENERATION Glitch My gearbox is a nut short Fix One of the most infamous flaws in Second Generat
13. 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 CATEGORY 19 STEERING TSB MODELS SUBJECT DESCRIPTION 19 03 99 94 99 BR Steering slow to return to center 05 07 99 This bulletin supersedes technical service bulletin 19 01 94 dated January 28 1994 This bulletin applies to 4x4 vehicles equipped with a Dana model 60 front axle sales code DRD The rate of steering return to center after turning a corner may be slower than normal or may require slight steering wheel correction while driving straight ahead The repair involves performing a ball joint tightening sequence 19 04 99 99 BR Steering system diagnosis 05 28 99 Customers may complain that the steering system feels heavy or the steering wheel is not centered while driving on a straight road The steering gear used on the 1999 Ram Truck is designed to have a heavy on center steering characteristic Before replacing a steering gear for a steering system feel complaint perform the suggested diagnosis to ensure that the rest of the steering system components perform as designed CATEGORY 21 TRANSMISSION TSB MODELS SUBJECT DESCRIPTION 21 08 99 96 99 BR Buzz whi
14. states of CA ME MA 4 10 differential 21 000 GCWR 20 000 GCwr for the states of CA ME MA 3500 single or dual wheels regular cab and quad cab 4x2 and 4x4 47RE automatic transmission 235 hp engine 3 73 differential 18 000 GCWR 17 000 GCWR for the states of CA ME MA 4 10 differential 20 000 GCWR 19 000 GCWR for the states of CA ME MA 3500 regular cab and quad cab 4x2 and 4x4 six speed or 48RE transmission High Output 305 hp engine 3 73 differential 21 000 GCWR 4 10 differential 23 000 GCWR Summary Varies with model and options Maximum tow rating is a 3500 series with standard cab long bed manual transmission 4x2 4 10 axle ratio 23 000 GCWR Cab Chassis Models Not ofered by the factory However commercial owners could order a box delete option Comments This all new body and cab interior layout also features options not previously offered American rear axle features a larger ring and pinion set for greater strength and durability New body gets new exterior paint colors and new interior upholstery colors and options Cummins badging is moved form front doors to front fender edges near bumper At mid year the 47RE automatic transmission was discontinued The 305 hp High Output engine was matched to a NV5600 six speed manual transmission and a new 48RE automatic transmission Dawna Eickhoff A 03 newer Third Generation truck TDR Member Archives 10 2
15. vented straight overboard Occasionally some oil would find its way into the blow by tube and eventually drip out the bottom When Second Generation trucks came out this problem also resulted in a lot of erroneous front differential yoke seal replacements because the engine oil not differential fluid dripped down in the same area Of course if Dodge hadn t moved the differential from the right side to the wrong side this problem wouldn t have existed Most people simply put a small bottle with some holes in the side on the bottom of the vent tube it could still breathe but the oil was trapped in the bottle Dodge did this for 2001 but most oil change locations forget to empty it and when it fills the fan blows oil all over the place On 24 valve engines the breather moved to the front and any truck on a steep descent could lose a lot of engine oil as crankcase pressure pushed it out the tube Cummins offers a fix that moves the breather inlet back alongside the engine where it is less affected by crankcase oil level on steep grades tright where it was on 12 valve engines Dodge TSB 09 002 02 Crankcase Breather Overflow 138 page 84 Ref 24 p 17 The old cotton sock idea is an easy fix with no drips or oily film on anything but the outer sock replace the sock while am under the truck changing oil extended the tube and drip catch bottle down to the anti sway bar and secured it with a couple of wire ti
16. wheel causing the wheel to jam recalls for various covers to be installed on steering shaft linkages and headlight switches burning out Major owner gripes centered around poor fuel filter and oil filter access moisture intrusion and retention into cab and cab doors vision obstruction by the A pillars poor adhesion of certain colors of paint failure of the OEM Goodyear tires to maintain their balance loss of fifth gear in the manual transmissions fraying of the unsheathed throttle cable Conclusions These trucks have proven to be very durable though not particularly good looking after several years of use Owners have reported driving them in excess of one million miles without any major internal engine work 1995 Turbo Diesel What is New Extended cab Revised paint schemes and colors Models Available 2500HD as standard cab extended cab long bed 4x2 and 4x4 3500 same as above Engine Ratings Same sas 1994 model year 175 HP and 420 ft lbs for manual transmission 160 HP and 400 ft lbs for automatic transmission Transmissions No changes from 1994 Five speed manual 4500HD 5th overdrive Four speed automatic 47RH 4th overdrive with locking converter Maximum Tow Ratings 2500 and 3500 3 54 Axle maximum GCWR is 14 100 pounds 4 10 Axle maximum GCWR is 16 000 pounds Cab Chassis Models None Comments The 1995 model is largely a carryover from the 1994 model year with the exception of
17. you remove the dipstick tube Replace the O ring for a quick fix FILTER TIPS If your engine oil filter or fuel filter simply refuses to budge when you re trying to remove it let the engine fully cool off and it may be much easier to remove To make the job of removing your oil filter easier and neater put on a pair of surgical gloves They improve your grip and keep your hands clean When the filter is off the vehicle simply hold the filter top with one hand and with the other pull the glove off your hand by turning it inside out over the top of the filter Then oil can t get out of the filter opening Acommonsense reminder before installing a new oil or fuel filter write the date and mileage on the filter with a marker to make remembering these vital details easier Also before installing a new oil filter or a new diesel fuel filter prime it with the appropriate fluid first Get the filter as full as possible Have you found yourself with a difficult to remove oil filter You tried with no avail the band wrench strap wrench and filter claw tool that you found at the auto parts store You tried the screwdriver through the side of the filter trick only to have the screwdriver twist in place Your last resort try a hammer and chisel to the top edge of the filter housing Oh yeah be sure to knock the chisel in the counter clock wise direction as viewed from the bottom of the filter Best ever filter removal
18. 07 DR DH D1 DC Remote start system Diagnostic chart for antenna 01 27 07 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 07 DR Flash Sunroof module excessive ignition off draw pop in radio with ignition off dome lamp 06 06 07 flickers and may not go off This bulletin involves selectively erasing and reprogramming the Sunroof Motor Module with new software 08 018 07 07 DR DH D1 DC Mopar remote start system RKE intermittent operation or alarm may sound 06 23 07 This bulletin involves the installation of a Mopar remote start system service repair kit 08 007 08 07 08 REV A Engine does not crank or start due to electronic lockup of the remote key module 7 4 08 This bulletin applies to vehicles built on or before May 05 2008 The customer may experience ano 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 t
19. 12 valve engines were a problem recall reading the Backfire column in Issue 39 where the editor states The old 12 valve engines used a mechanical fuel pump the type driven off the engine s camshaft which is essentially problem free Nevertheless as started to read more about the transfer pump for 12 valve engines on the TDR website it became obvious that there are many instances of pump failure Is this something that we 12 valve owners should be watching out for Warning Signs The first sign suggesting that my pump might be failing was very hard startups in the morning Then noticed that the idle rom was slowly getting lower and when driving the truck it had lost its pep Finally the truck just wouldn t start After running a fuel pressure test to determine the problem concluded that it was the fuel lift pump You can purchase a new lift pump from a Cummins distributor for around 170 00 part number 3936316 gaskets 3939258 at 1 68 Replacement Following the procedure in the Service Manual the first step is to disconnect the battery terminals The instructions read to remove the starter motor Remove the starter there has to be a better way place a drain pan below the pump remove the fuel line fittings at the top of the fuel pump and fuel heater housing Next remove the fuel hose clamps and rubber fuel hose You can leave them connected and remove after you have removed the fuel pump and
20. 18 235 2700 420 1600 2279 2514 Manual CARB 18 2617 EPA 18 215 2700 420 1600 Auto 99 2619 CARB 18 24 Valve 2616 EPA 18 235 2700 460 1600 Manual 2618 CARB 18 2660 EPA 18 215 2700 420 1600 Auto 00 2661 CARB 18 24 Valve 2662 EPA 18 235 2700 460 1600 Manual 2663 CARB 18 2865 2902 EPA 19 5 Auto 2866 2903 CARB 19 5 235 2700 460 1600 01 2496 2904 EPA 19 5 5 Manual 24 Valve 2497 2905 CARB 19 5 2415 2906 EPA 19 5 245 2700 505 1600 6 Manual 2495 2907 CARB 19 5 8030 EPA 19 5 Auto 8031 CARB 19 5 235 2700 460 1600 02 8032 EPA 19 5 5 Manual 24 Valve 8033 CARB 19 5 8034 EPA 19 5 235 2700 505 1600 6 Manual 8035 CARB 19 5 8216 47RE Auto CARB Catalyst equipped 23 235 2700 460 1400 8224 5 Manual 5 i i 23 03 2624 48RE Auto EPA Non Catalyst 23 5 9HPCR 250 2900 460 1400 3 8223 5 Manual 23 305 2900 555 1400 2998 6 Manual 26 A Publication of the TURBO DIESEL REGISTER 1 18 Boost Model Year HP RPM Torque RPM CPL Transmission Comments Specification 8216 47RE Auto CARB Catalyst equipped 23 235 2700 460 1400 8224 5 Manual i i 23 03 2624 47RE Auto EPA Non Catalyst 23 5 9HPCR 250 2900 460 1400 8223 5 Manual 23 305 2900 555 1400 2998 6 Manual i 26 8410 48RE Auto CARB Catalyst equipped 23 2
21. 24 98 08 51 98 11 27 98 08 54 98 12 30 98 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 89 93 AD Installation of radio transmitting equipment 94 99 BR This bulletin supersedes technical service bulletin 08 22 95 dated May 12 1995 This information only TSB is provided to assist in properly installing communication equipment in Chrysler vehicle This information should be given to any owner inquiring about installing radio transmitting equipment 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 deactiva
22. 350 3000 ae 6 7 HPCR 650 1600 1490 68RFE Auto All Certifications 28 08 8235 6 Manual All Certifications 26 Cab 305 2900 610 1600 Chassis 2886 Aisin Auto All Certifications 26 09 610 1600 1489 6 Manual All Certifications 28 350 3000 ae 6 7 HPCR 650 1600 1490 68RFE Auto All Certifications 28 09 3500 2780 6 Manual All Certifications 26 Cab 305 2900 610 1600 Chassis 2775 Aisin Auto All Certifications 26 09 4500 2779 6 Manual All Certifications 26 5500 Cab 305 2900 610 1600 Chassis 2774 Aisin Auto All Certifications 26 The boost numbers for the 07 5 and newer 6 7 liter engine applications are approximate There can be variance based on the amount of exhaust gas recirculation in the intake air the intake thro the opening and variable geometry turbocharger s position As aside note did you notice how uncluttered the table was in the early years Compliance with emissions leglislation can make things complicated Now that you have the specifications in hand wait a minute you don t have a boost gauge This instrument is easy to source relatively cheap 40 60 and easy to install The majority of gauges on the market are mechanical devices that do not require electricity to operate To put a gauge in one can use a boost bolt to access the pressurized intake air As mentioned with a gauge installed you can use the boost readings as a diagnostic check of the
23. Bill my Mastercard VISA Model Ld S Juyers Oo e j Julide Table of Contents Looking at the Changes 3 Buying a Used Truck 05 20 Dodge Technical Service Bulletins 22 TSBs Issued During 95 and Prior 23 TSBs Issued During 96 TSBs Issued During 97 TSBs Issued During 98 TSBs Issued During 99 TSBs Issued During 00 TSBs Issued During 01 TSBs Issued During 02 TSBs Issued During 03 TSBs Issued During 03 07 76 Recall Notices ccccceeeeeeeeees 96 Most Common Problems 99 Favorite Fumbles Fabulous Fixes 99 12 Valve Dowel Pin Common Sensical SOMMMON iaaa 104 12 Valve No Start Condition 107 Fuel Transfer Pumps Revisited 108 Low Pressure Fuel System Problems iea 126 Turbo TIPS 0c0ccceesssssseteaeeeees 130 Preventive Maintenance 133 Mechanics Tips 00000008 135 NEW OWNER S CORNER 138 Part Number Reference 139 Liquids in Your Truck 141 Memorable Articles State Zip Exp Date LOOKING AT THE CHANGES A TURBO DIESEL BUYER S GUIDE by Jim Anderson Aside from the quarterly column and articles that write for the TDR also serve as the e mail and call back guy Yep that means get lots of correspondence from those interested in th
24. Largest interior cargo valume 72 2 cubic feet Largest cargo volumne behind rear seat 7 7 cubic feet Largest flat floor load area 16 8 square feet Largest second row leg room 44 2 inches Largest rear door opening 34 5 inches wide 35 5 inches tall Largest rear door open angle 85 degrees First ever reclining rear seats 22 to 37 degree seat back angle Going hand in hand with the Mega Cab introduction Dodge redesigned the interior dash and seats A minor facelift to the truck s headlights bumper and grill were a part of the 2006 introduction In the spring of 2006 dodge introduced the Chassis Cab truck for commercial markets The truck started production in the summer months and was officially known as a 2007 model The engine for the Chassis Cab was a new 6 7 liter Cummins Turbo Diesel A Publication of the TURBO DIESEL REGISTER This 6 7 liter engine will be used in the pickup trucks in 2007 as it was designed to meet the tighter 2007 emissions regulations Models Available 2500HD as standard cab quad cab short bed long bed 4x2 and 4x4 3500HD same as above The dual wheel 3500 is not offered with a short box The Mega Cab is offered only with a short box With the dual rear wheel 3500 Mega Cab Dodge had to introduce a short box option Engine Ratings Again for 2006 the only engine offered is the 50 state approved 325 HP and 610 ft lbs torque Cummins Turbo Diesel T
25. 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 A Publication of the TURBO DIESEL REGISTER TSBs Issued During 95 and Prior CATEGORY 2 FRONT SUSPENSION TSB 02 05 95 5 15 95 02 02 94 2 11 94 02 07 94 6 15 94 02 08 94 7 22 94 02 20 94 12 2 94 02 02 91 1 28 91 02 06 90A 12 17 90 02 09 90 11 19 90 MODELS 94 95 BR 4x4 4x2 Cab Chassis 94 BR 94 BR 94 2500 BR Cab Chassis with sales code XBC 94 BR 92 AD 2wd vehicles only 90 91 AD 2wd vehicles only 89 90 AD 4wd CATEGORY 3 SUBJECT DESCRIPTION Rattling clunk type noise from front of vehicle Verify that the stabilizer bar is built with the correct ball stud links If necessary the bulletin details the replacement of both stabilizer links with tapered ball stud links Service manual revisions for torque values on front suspension This information bulletin differentiates the track bar used on different vintage trucks Low ride height on 8800 GVW cab chassis The bulletin describes abnormal low ride height in the rear where the truck is loaded near GVW It lists the parts necessary to replace the shocks and rear leaf springs Service manual revision for torque values on stabilizer link bar Front spring spacer for two wheel drive trucks The conditi
26. Performance www vulcanperformance com offer similar pump only kits for the 98 5 02 trucks Alternately you can become a fuel systems engineer and source a Holley Carter Walboro etc fuel transfer pump from a variety of automotive catalogs and retrofit a pump to your truck Moving to 650 The price tag moves to 650 when you take the performance type fuel transfer pump kit as offered by the vendors above and add to that kit a mounting block that holds one or two additional fuel filters In the quest for clean fuel and reliable fuel pressure this is the utmost solution 03 04 5 WHAT TO DO have a 03 Turbo Diesel Recently 45 000 miles the filter mounted fuel transfer pump stopped delivering fuel from the tank After a lot of looking around the Dodge mechanic was able to get the replacement pump supplied by Mopar These replacement pumps are in very short supply which leads me to think am not the only one with this original pump problem Am correct and can you give me any information on this Larry Durkee My response Larry wow In Issue 50 page 108 November 05 John Holmes reported that the 03 04 transfer pump failures would have to be fixed using the in tank designed fuel transfer pump After much research have concluded you were very lucky too have an 03 Turbo Diesel The warranty period has expired Your correspondence prompted me to call my Dodge dealer to order a spare fuel transfer
27. Publication of the TURBO DIESEL REGISTER Tl CATEGORY 8 ELECTRICAL Continued 08 031 03 10 31 03 08 011 04 3 16 04 08 014 04 3 30 04 08 014 05 2 17 05 08 024 05 5 4 05 08 058 05 10 29 05 08 014 06 3 16 06 18 03 DR PCM connector corroded sets MIL light This bulletin applies to vehicles equipped with a 5 9 liter diesel engine and an automatic transmission Water may enter the PCM connector causing corrosion of electrical terminals on the PCM This condition can set diagnostic trouble codes and illuminate the MIL light If diagnostic trouble codes are present or other diagnostics lead to PCM connector problems inspect the PCM and the PCM wire harness connector The repair procedure involves replacement of the wiring harness 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 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
28. REGISTER 33 CATEGORY 23 BODY Continued 23 101 94 94 95 BR 12 30 94 23 57 93 94 BR 10 8 93 23 64 93 94 BR 11 19 93 23 21 92 93 AD 9 8 92 23 09 91 92 AD 8 26 91 23 12 90 91 AD 10 8 90 23 24 89 90 AD 10 10 89 23 08 89 89 AD 4 10 89 CATEGORY 24 Anti friction tape on A pillar Bulletin 23 36 94 described a squeak and paint abrasion at the door to windshield A pillar area Anti friction tape is now being applied at the assembly plants to prevent the problem Do not remove the anti friction tape Instrument panel creak A creak or squeak may be present on the left side of the instrument panel The repair involves loosening of the instrument panel to provide additional clearance between the cowl side panel and instrument panel support joint Tailgate rattles If tailgate rattles over bumps check for looseness If tailgate does not close tightly replace the overslam and alignment bumpers 93 standard paint colors 92 standard paint colors 91 standard paint colors 90 standard paint colors 89 standard paint colors AIR CONDITIONING TSB MODELS 24 01 95A 89 94 AD 3 3 95 24 06 95 A 94 95 BR 5 26 95 24 08 95 94 95 BR 5 19 95 24 08 94 94 BR 5 6 94 34 SUBJECT DESCRIPTION R 12 to R 134a refigerant adaptation procedure The bulletin describes the conversion from R 12 to R 134a The proc
29. Regular Cab 4x2 4 790 16 150 Regular Cab 4x4 5 120 16 750 Quad Cab 4x2 4 480 16 150 Quad Cab 4x4 4 780 16 750 Mega Cab 4x2 3 200 15 550 Mega Cab 4x4 2 770 16 100 2009 Turbo Diesel What is New Although the Dodge Ram 1500 model received a new body and interior the Turbo Diesel 2500 and 3500 consumer pickups and 3500 4500 5500 Chassis Cab trucks saw only minor trim revision sin this carryover transitional model year Models Available Same as 2006 2007 and 2008 2500 HD as standard cab quad cab with short bed or long bed in 4x2 and 4x4 configurations 3500 HD same as above although the dual wheel 3500 is not offered wiith a short box The Mega Cab is available in the 2500 or 3500 single rear wheels or 3500 dual rear whels It is only offered with a short cargo box Chassis Cab Models Same as 2008 The 3500 is available in single or dual rear wheels The 4500 and 5500 are dual rear wheels All three Chassis Cabs are available with a regular cab or Quad Cab configuration With the 3500 the regular cab can be purchased with a 60 inch cab to rear axle length or a 84 inch cab to axle length with single or dual rear whels SRW DRW The 3500 Quad Cab can only be purchased with the 60 inch cab to rear axle lenth with SRW or DRW The 4500 and 5500 trucks are only offered with dual rear wheels These trucks allow regular cab or Quad Cab cabins to be used with the 60 inch or 84 inch cab to axle length 14 Engine Ratin
30. SUBJECT DESCRIPTION 21 02 00 99 00 BR 47RE transmission delayed upshift or no TCC engagement between 30 and 50 MPH 03 10 00 This bulletin applies to vehicles equipped with a federal market 5 9L 24V diesel engine and built between March 2 1999 and October 1 1999 The customer may experience a condition where the transmission may seem to have a delayed 3 4 upshift while moderately accelerating from 30 to 50 MPH The customer may also note high engine rpm s while operating in third or fourth gear This condition may be caused by a delay in the engagement of the transmission torque converter clutch torque converter lockup The repair involves the replacement of the transmission valve body upper housing separator plate 21 04 00 96 99 BR Erroneous MIL illumination for P1763 Transmission Governor Pressure Sensor Volts Too High 06 30 00 Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code DTC of P1763 Transmission Governor Pressure Sensor Volts Too High The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear limp In mode as a result of the DTC The Limp In mode may last until the vehicle owner cycles the ignition key The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive The MIL is caused by an increase in hydraulic pressure The increase
31. Spicer 1310 series front u joint A rebuilt driveshaft with a 1350 u joint solves the problem and owners with a lifted truck are cautioned to check the Cardan joint cage clearance at the back of this driveshaft Glitch My windshield squeaks Fix All trucks squeak but this problem applies only to First Generation trucks and involves the bodywork cracking more literally breaking apart at the cowl near the lower corners of the windshield TSB 23 63 94 showed the parts steel stampings and procedure for repairing the problem The adhesive mentioned in the TSB has been discontinued and 3M Panel Bonding Adhesive recommended as the substitute Ref 33 p 41 Glitch My automatic is too automated Fix If your automatic transmission truck changes its mind a lot about what gear to use don t start with the gearbox but check the throttle position sensor The letters TPS are as well known to readers as this infamous part could be a major nuisance The TPS failure is characterized by a 100 200 rpm swing as the torque converter clutch locks and unlocks repeatedly while the transmission remains in 4th overdrive gear Clean it and the connectors yourself or get a new one chances are if it hasn t gone bad it will Do not confuse a TPS failure with a TTS Transmission Temperature Sensor failure which is characterized by a 200 400 rpm swing as the transmission cycles between 3rd and 4th gear Replace the TTS and check the connectors
32. The 24 valve engine s VP 44 fuel injection pump relies on fuel from the transfer pump to keep the VP 44 s internal parts lubricated and cool A bad fuel transfer pump and the transfer pump is known to be problematic means a loss of fuel pressure to the VP 44 and often leads to the demise of the very expensive VP 44 injection pump A fuel pressure gauge for a 24 valve engine is mandatory Andy mentions that a possible negative would be if a failure of the new transfer pump now located in the tank is experienced the additional labor required to drain drop the fuel tank and service the module pump assembly could be more expensive Change the words could be more expensive to would most definitely be A Publication of the TURBO DIESEL REGISTER more expensive Add to the cost factor the realization that an on the road failure These failures do not happen as you re pulling into a Dodge dealership do they is now an expensive towing bill or a major time waster even if you have the tools to swap a fuel transfer pump on the side of the road Yeah right change it on the side of the road My keep it simple solution of having a spare lift pump will be complicated by misinformation in the field Owners are being told that they can no longer purchase the lift pump at their Dodge dealership Regardless of the story from Mopar there is good news for 98 5 02 owners from the rest of the parts aftermarket The
33. and the 8 0L V10 gas engine or the 5 9L Cummins diesel engine The problem described is that the transmission operates normally through all ranges except fifth gear The 14 page bulletin describes the proper repair procedure CATEGORY 23 BODY TSB MODELS SUBJECT DESCRIPTION 23 13 98 98 BR Rear sliding window difficult to open will not remain latched and or leaks water past the lower 5 8 98 run channel If the rear sliding window is difficult to open will not latch and or leaks water past the sliding rear window s lower run channel this bulletin describes the proper diagnosis repair 23 16 98 98 BR Splash guards mud flaps discolored and or distorted due to proximity to tailpipe 5 1 98 This bulletin applies to vehicles equipped with dual rear wheels Vehicles equipped with splash guards may experience discoloration and or distortion along the outside edge of the passenger side rear splash guard due to the proximity to the tailpipe If necessary a new tailpipe assembly is installed 23 17 98 94 98 BR Center armrest driver side hinge cover broken 5 1 98 If the center armrest upper inertia latch cover driver side hinge cover is broken the proper repair involves replacement of the hinge 23 35 98 94 99 BR Door trim panel retainer clip attachment breakage when door trim panel is removed for service 8 7 98 The bulletin cautions the dealer that damage to the door trim panel may occur if the door trim
34. applications Also part no 7 is different as well Last but not least as evidenced by the numbers of problems that this hose has caused is the rubber fuel return line The illustration shows the rubber line used on a 98 12 valve The 94 97 trucks use a rubber line 5 16 that is about three times as long The illustration is misleading This hose is very difficult to see and access as it is tucked behind the fuel filter assembly Engine heat and age will cause this hose to develop cracks It will leak air first then fuel Many owners report the use of a silicone grade marine fuel line as a permanent repair I ve had good luck as well with a Gates fuel injection hose which seems to withstand the heat and elements far better than the factory supplied SAE J 30R7 rubber fuel line find it helpful to remove the fuel filter base from the engine when changing the rubber return and or supply lines The lines can be gently slipped out of the brackets at the bell housing to provide better access also like to have a fresh razor blade handy to split the old lines where they are often stuck onto the metal fuel piping Some fresh stainless steel clamps are smart too will leave you with a list of part numbers that may help you in sourcing parts Be advised that the part numbers may have been superseded Andy Redmond Redmond Enterprises and Engine Repair Plano Texas C
35. 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 DTC s listed above are present perform the repair procedure Overhead console temperature reading inaccurate or dome lamp turns off too soon This bulletin supersedes technical service bulletin 08 026 06 dated June 02 2006 This bulletin involves selectively erasing and reprogramming the cabin compartment node CCN with new software This bulletin applies to vehicles built on or before May 30 2006 The vehicle owner may notice that if a vehicle door is left open for longer than 20 seconds the illuminated interior dome lamps will turn off Or the vehicle operator may report that the ambient temperature first displayed in the overhead console is not accurate displays 40 C or 40 F when the ignition switch is turned to the On position then slowly updates to the outside ambient temperature as the vehicle is driven If the vehicle operator describes or experiences the symptom condition perform the repair procedure which involves a reflash to the CCN Steering angle sensor over travel performance DTC C 1240 This bulletin involves the diagnosis and possible replacement of the steering angle sensor This bulletin applies to vehicles equipped with the Electronic Stability Program sales code BNB and built prior to October 03 2006 The custome
36. connection is made by a rubber supply line elbow that makes a sharp ninety degree bend change this rubber elbow item 11 when a transfer lift pump is serviced Often this line is a major source of air leakage and subsequent fuel aeration As confirmation of my replace the elbow service technique had a discussion with a friend who is a competent technician He had replaced a lift pump and now the truck would not restart He stated that the lift pump would raise fuel up to the air bleed port on the fuel filter outlet but with many bubbles rather than a clear stream of fuel After we discussed probable causes he called me back a short time later to report his findings Sure enough the rubber elbow was sucking air when the lift pump was manually primed He also noted fuel weeping into the electrical connector on the fuel heater and a bad seal at the upper base and the upper heater quad ring o ring with square vs round sides Since he was short of parts he removed the constant tension clamps and added gear drive type clamps to the rubber line and removed the fuel heater and upper o ring After about twenty strokes on the primer and the truck started right up The next component the heart of the low pressure fuel system for 12 valve owners is the fuel transfer or lift pump Note to 24 valve owners you can stop reading at this point don t want to discuss your electronic fuel transfer pump The lift pump is a piston style
37. covered under the provisions of the warranty The component parts are covered under the appropriate Mopar part warranty DaimlerChrysler Corporation is now offering airbag on off switches for the selected vehicles listed above The switches are packaged in a kit containing all necessary parts except as indicated and a detailed instruction sheet Under the National Highway Traffic Safety Administration s rule consumers will be authorized for on off switches by claiming they meet any of several criteria Airbag on off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter For more information concerning the authorization process and or the authorization letter call NHTSA s Auto Safety Hotline at 1 800 424 9393 We encourage the dealer to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization 64 A Publication of the TURBO DIESEL REGISTER CATEGORY 9 ENGINE TSB 09 002 01 03 02 01 09 001 01 1 19 01 09 003 01 5 4 01 09 004 01 5 18 01 09 006 01 08 24 01 09 002 02 3 11 02 MODELS SUBJECT DESCRIPTION 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 w
38. 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 A Publication of the TURBO DIESEL REGISTER 35 TSBs Issued During 96 CATEGORY 2 FRONT SUSPENSION TSB 02 01 96A 5 31 96 02 03 96 5 31 96 02 04 96 6 21 96 02 06 96 11 29 96 MODELS SUBJECT DESCRIPTION 94 96 BR Camper Special service kit The bulletin supersedes TSB 02 01 96 dated 3 15 96 The bulletin applies to body style codes 31 32 and 62 with one of the listed GVW sales codes Z2B Z3A Z7B Z8A or Z8B The bulletin describes the parts and installation procedure for a special service kit developed for use by owners that consistently carry a box mounted camper A rear stabilizer bar and auxiliary spring comprise the kit 94 96 BR Creaking noise from rear of vehicle The diagnosis involves the inspection of the rear leaf spring assembly to verify the appropriate number of spring tip inserts are present If tip inserts are broken or missing the repair procedure is detailed in the TSB 94 96 BR Lower ball joint replacement Two wheel drive This bulletin applies only to two wheel drive vehicles It discusses the service differences in tack 2WD welded ball joints control arms and non tack welded ball joints control arms 94 97 BR Track bar ball joint diagnosis 4x4 only The bulletin refers to the 97 Truck Service Manual and is a
39. do not know of any product other than the recommended Mopar fluid that could or should be considered for use For lack of verifiable information stay with the factory recommended Mopar friction modifier for your 89 02 limited slip differential In 2003 Dodge changed from Dana to American Axle as the vendor of the front and rear differential units From my 2003 and 2007 Owner s Manual Limited slip rear axles do not require a limited slip additive The Owner s Manual states fluid changes should be done every 15 000 miles for schedule B service A Publication of the TURBO DIESEL REGISTER TRANSFER CASE Wow here is another easy one The manual reads Use Mopar ATF 4 Automatic Transmission Fluid Type 7176 or equivalent or a fluid of the type labeled Merco or Dexron Ill automatic transmission fluid It is easy to find the Mopar ATF 4 7176 at the local parts store For simplicity would suggest using the ATF 4 in the transfer case too ANTIFREEZE COOLANT Many owners have heard the truck stop stories about special additives and conditioners that are necessary in diesel engines These stories are occasioned by a problem called cavitation erosion pitting of they cylinder walls due to the implosion of air bubbles in the cooling system which does occur in many diesel engines But the answer is not to be found in a special brew for your Turbo Diesel engine For a complete technical discussion see Issue 54
40. draining the lube from five speed manual transmissions remove the PTO cover from the side of the transmission Start with the bottom bolt as it acts as a drain plug Refill with synthetic gear oil in 75W 90 or 80W 90 weights with a GL 4 rating Often members will ask about the GL 4 rated Castrol Synthetic gear lubricant 75W 90 specified for the five speed NV4500 manual transmission If the GL 4 classification is good shouldn t a GL 5 rated lubricant be better It may seem reasonable but in the case of the NV4500 gearbox not necessarily so The GL 5 oil contains twice the amount of sulfur phosphorous additive package as GL 4 At high temperatures the phosphorous plates out and reduces the coefficient of friction of the synchronizer rings New Venture Gear has seen this on shift stand tests Since there s twice as much of it there s more of a detrimental effect compared to GL 4 23 BODY Because a diesel engine vibrates more than its gasoline engine counterpart all fasteners should be checked periodically for tightness Also body fasteners and bracket fasteners which might vibrate in sympathy with engine vibration should be checked for tightness If the GL 4 classification is good shouldn t a GL 5 rated lubricant be better A Publication of the TURBO DIESEL REGISTER MECHANICS TIPS Here s a collection of tips to help the mechanic handyman while working on his or her vehicle These tips have been collected by the
41. editor over a period of years from many different magazines and other sources and have been organized into categories for easier reference WORK ENVIRONMENT First here are some tips from the pros about your work environment e Never wear rings or other jewelry while working on your vehicle Jewelry can scratch paint get caught in turning belts cause wiring short circuits and otherwise ruin your day e Keep your work area and tools clean neat and organized That way things will be easier to find when needed and safer to use e Wipe up floor spills before you slip and fall Keep tools free of grease and oil so your hands won t slip off e Place removed parts in a safe place so you won t trip over them while moving around the vehicle e Provide proper light for a better quality repair e Provide adequate ventilation if you are using chemicals or fuel as a solvent e Adequately support the vehicle on jack stands if you are working underneath it Use jacks and chains to support or move heavy loads e Never put a tool back in the toolbox without first cleaning it to be ready for the next use VEHICLE TRIM If your pickup has a top over the bed wedge a section of foam pipe insulation across the bottom of the bed where the tailgate closes against the bed This will keep most dust and water out of the bed interior If you install carpet remnants in your cab or truck bed you ll soon find that the cut edges will fray To
42. engine s performance The engine will need to see a full throttle loaded condition in order to make its maximum boost number The easiest way to do this is to drive the truck up a hill No hills in Kansas Apply the brakes to load the engine A Publication of the TURBO DIESEL REGISTER How did your truck perform on the boost test we suggested If your truck didn t seem up to par there are several simple checks you can do before you take the truck to a service location The following are some of the do it yourself areas to check e Check for quality of fuel e Check for full travel of the throttle lever at the fuel pump Check all turbo to intercooler intercooler to intake manifold hoses and clamps for a tight fit Check the condition of your fuel filter Check for fuel inlet restriction Check the condition of your air filter Check for exhaust leaks prior to turbocharger Check for exhaust system restriction For automatic trucks check your transmission fluid level Hopefully our discussion on boost specifications and the use of turbo boost as a diagnostic tool will help you to ensure the best performance of your truck Happy motoring Robert Patton TDR Staff 19 20 BUYING A USED TRUCK By Jim Anderson When you buy a new truck you are protected by a manufacturer s warranty and the integrity of the dealer from whom you purchase When buying a used vehicle you are much less protected by the law and frequently
43. established Step by step instructions help the technician identify and repair the problem 82 A Publication of the TURBO DIESEL REGISTER CATEGORY 14 FUEL Continued 14 005 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 07 27 06 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 14 007 06 06 07 DH D1 DC Fuel and fuel filtering requirements for Cummins 5 9 liter and 6 7 liter engines Rev A This bulletin supersedes technical service bulletin 14 007 06 dated August 25 2006 09 02 06 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 eng
44. 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 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 03 07 Cummins diesel diagnostics Rev A DR DH D1 DC This bulletin applies to vehicles with the 5 9 liter engine sales code ETH or ETC 10 27 06 Revised diagnostic procedures are available for the following conditions Engine cranks for a long time or will not start e White smoke and or misfire after starting when the engine temperature is below 150 F Engine surges at idle 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
45. for cylinder head bolts 89 AD with automatic Knocking noise at rear of engine due to a cracked torque converter drive plate 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 21 CATEGORY 11 EXHAUST TSB MODELS SUBJECT DESCRIPTION 11 03 94 94 BR Diesel exhaust stains 5 13 94 The bulletin applies to 5 speed trucks built prior to 2 1 94 and automatic trucks between 2 1 94 and 10 1 94 The condition is exhaust soot on the side of the truck A tail pipe extension is the part needed to remedy the situation 11 02 92 88 92 AD Rear tailpipe support bracket cracking 7 27 92 The condition is a rattle noise caused by a crack or break in the rear tailpipe support bracket area A revised tailpipe support bracket 5 2018458 is the part used for repair CATEGORY 14 FUEL TSB MODELS SUBJECT DESCRIPTION 14 05 94 94 BR Use of low sulfur fuel 4 8 94 89 93 AD The bulletin discusses the new for 1994 low sulfur fuel Fuel lubricity concerns are addressed as the use of diesel fuel additives to increase the lubricity of low sulfur fuel are not required 14 15 93 89 93 AD Fuel leakage from the roll over valve vent The bulletin warns that repeated attempts to force fuel into the tank after the automatic shut off has engaged may lead to a condition where the fuel
46. from CH to the newly released CJ and the ATF fluid from Mopar 7176 to 7176 4 The ATF is backward compatible 143 144 Memorable Articles In Issue 41 we made mention of several surveys that we conducted at the TDR website As a follow up think you ll find the following questions and answers of interest for we have tried to summarize and add reference listings for this valuable information What is your most memorable article from the TDR The responses to this question were refreshing and energizing to all who contribute their articles whether it be the staff or a member write in A couple of examples of comments we received include these there are so many memorable articles that my truck would not be where it is now if had not joined the TDR I hope that is a good thing I first read the TDR in the spring of 97 It sold me on the Dodge Cummins combination and ordered one of the first 99 models with the six speed transmission Several names appeared frequently in responses to the survey Is there a risk of giving these guys an inflated ego think not as the writers are all down to earth guys that take pride in their work and enjoy teaching what they have learned Contributions by writers particularly appreciated by the readership include the following Anything technical by Joe Donnelly the travel adventures of Bill Swail s EarthRoamer truck Will the articles have the same interest level now
47. higher than normal steering wheel movement perceived as excessive play is required to keep the vehicle going straight or if over compensating the steering to keep the vehicle from wandering is a condition the bulletin describes the diagnosis and repair procedure The repair involves adjustment of the over center and if necessary the worm thrust bearing preload adjustments on the steering gear 19 16 97 94 97 BR Lower steering column noise and or minor lower steering column movement 11 28 97 This bulletin applies to vehicles built before Dec 31 1996 and describes a lower steering column noise and or minor lower steering column movement If movement in the steering column is greater than the tolerance the repair involves adding a toe plate shim to the steering column CATEGORY 21 TRANSMISSION TSB MODELS SUBJECT DESCRIPTION 21 12 97 96 97 BR Transfer case shifter buzz or rattle 8 29 97 This bulletin supersedes TSB 21 13 96 dated 9 20 96 A buzz or clatter may be heard from the 4x4 transfer case shifter at an engine speed of approximately 2000 rpm The condition may 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 A Publication of the TURBO D
48. inaccuracy If the fuel gauge reads inaccurately too much reserve when the tank gauge reads empty a revised fuel sending unit may be necessary Trailer tow brake wire location An information only bulletin showing the wiring provisions for an electric brake actuator Power mirror vibration On vehicles equipped with power mirrors built prior to 9 18 94 this TSB discusses the diagnosis and repair for excessive vibration blurred images Poor AM radio reception On vehicles built prior to 12 01 93 poor AM reception can be repaired by replacement of the antenna base and cable assembly White smoke at start up Service changes to the powertrain control module SEBC may cause white smoke at start up The SEBC is programmed to eliminate operation of the air intake heater for the first 25 vehicle starts After service or in predelivery situations there may be vehicles that have not accumulated 25 starts The white smoke condition should be resolved after 25 starts are accumulated Speed control surge The bulletin describes the correct speed control servo and cable match for the powertrain control module Verify compatability of components Replace speedometer drive gear if necessary A Publication of the TURBO DIESEL REGISTER CATEGORY 8 ELECTRICAL Continued 08 45 93 10 8 93 08 47 93 10 15 93 08 58 93 12 10 93 08 67 93 12 31 93 08 05 91 4 22 91 08 10 91 9 9 91 08 11 91 10 7 91 94 BR
49. is located on the front left side of the engine affixed to the gear housing Anoise may be present which on initial investigation may sound like a noisy turbocharger bearing The sound of the noise may be described as a whistle a squeal a howl a moan or a gurgle The noise will be more noticeable as engine temperature increases The noise will most often occur when the warm engine is operated between 1 500 and 2 200 rpm s The noise is usually heard in the cab louder on the passenger side or seems to come form the dash vents The noise may be caused by the coolant supply hose connector The connector is located on the cylinder head next to the turbocharger The connector is used to supply coolant to the heater hose The bulletin describes the replacement of the hose connector CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS SUBJECT DESCRIPTION 18 02 99 98 99 BR Erratic torque converter clutch TCC operation 02 19 99 This information applies to vehicles equipped with a 5 9L 24 valve diesel engine and automatic transmission built between January 1 1998 and December 18 1998 Some vehicles may exhibit a surge like condition while in fourth gear This may be caused by the TTC unlocking and locking when it should be consistently locked The cause of this erratic operation has been identified as electrical noise from the Throttle Position Sensor TPS or Alternator This bulletin involves selectively erasing and reprogramming the Powertra
50. keep the edges looking neat lay the carpet on a concrete floor lay a piece of metal 1 8 inch from the edge then heat the carpet edge with a propane torch Use care not to get the carpet too hot as you simply want to melt the synthetic fibers enough to seal the edge from unraveling This tip will not work on carpet with all natural fibers Practice on a scrap piece first Wrap a fingertip with duct tape glue side out A Publication of the TURBO DIESEL REGISTER TAKE IT OFF When you disassemble any piece of mechanical equipment you will end up with a bunch of random fasteners and pieces and can easily forget your re assembly order or you can lose one or more fasteners Use several small plastic tubs to hold stuff and or a large plastic tray where parts and fasteners can be laid out in the order they were removed Just turn the tray around for re assembly in order If you leave your worksite cover the tray or tubs with plastic food wrap to keep things from being disturbed For long term disassembly a freezer bag marked with the content description is a good alternative STUBBORN FASTENERS If your screwdriver slips off a Phillips or slot head screw when you try to loosen it put a bit of grinding compound in the slots to increase the screwdriver s grip on the fastener Another method is to strike the end of the screwdriver with a hammer while twisting it to break the fastener loose This works particularly well on aluminum
51. level in the tank is above the designed operating level Fuel may leak out of the roll over valve in this situation The repair involves raising the roll over vent location by installing fuel hose to the vent nipple and routing to a high location along the filler tube 14 02 90 89 90 AD Accelerator pedal effort too high 12 3 90 The bulletin describes the installation of revised parts to lessen the pedal effort If the truck has a Mopar aftermarket speed control kit the kit already has the revised parts 14 01 89 89 AD Injection pump diagnosis procedure 10 2 89 A troubleshooting procedure is outlined to help diagnose diesel engine problems CATEGORY 16 PROPELLER SHAFTS amp U JOINTS TSB MODELS SUBJECT DESCRIPTION 16 02 95 94 95 BR Droaning noise vibration 11 3 95 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 94 95 BR Shudder at start on vehicles with two piece driveshafts operated at near maximum GVW 10 14 94 The symptom is a driveline shudder when pulling away from a stop As the vehicle is loaded the driveline angle will change In the case of maxim
52. lube filters the numbers on the left are paper cellulose media design The numbers to the right are Microglass or StrataPore design Belt part numbers are Dayco Hose part numbers are Dayco and Mopar Hoses are listed with upper hose top and lower hose bottom of chart FUEL FILTER LUBE FILTER AIR FILTER BELT MODEEYR PART PART PART Assumes A C HOSES 5083285AA 2008 FS43252E 3949561 53034051AB 53041138 oe i LF3972 LF16035 5083285AA Ene FS43252E 3949561 53034051AB 53041138 eee LF3972 LF16035 O90 Pees ABS 79003209AA 53032700AB 52028872 U 2007 3942470 3949561 PE 53041138 pera FS19800E LF3972 LF16035 DSO TO SeUNB F9003209AA 53032700AB 52028872 U 2006 3942470 3949561 oe 53041138 Snel FS19800E LF3972 LF16035 DO oso TAB 0020A 53032700AB 52028872 U 2005 3942470 3949561 pais 53041138 eee FS19856E LF3972 LF16035 05015581AB gt 4 90832854A 53032700AB 52028872 U 2004 3942470 3949561 Riess 53041138 neler FS19856E LF3972 LF16035 OOO Toe TAR OCs ONG 53032700AB 52028872 U 2003 3942470 3949561 pees 53041138 SeN FS19856E LF3972 LF16035 05015581AA 05016547AB 4728406 bee 2002 3942470 3937145 3097074 5080810 ae FS19855E LF3059 LF3894 AF25541 05015581AA 05016547AB 4728406 erie 2001 3942470 3937145 3097074 5080810 Sees FS19855E LF3059 LF3894 AF25541 05015581AA 05016547AB 4728406 aE 2000 3942470 3937145 3097074 5080810 Bere FS19855E LF3059 LF3894 AF25541 04883963AB 05016547AB 4728406 ahe
53. malfunction indicator light MIL as required In addition the OBD system may cause these trucks to fail an inspection maintenance test and may not store mileage as required for certain transmission faults Repair The oxygen sensor module must be replaced and the engine control module ECM must be reprogrammed flashed The new software will also improve vehicle drivability and reduce the potential for exhaust soot accumulation in the vehicle s particulate filter The recalibration of the ECM updates and supersedes TSB 18 033 07 Revision B dated 6 28 07 see page 63 for details Wow what a listing of information Thanks again to the TDR members that forward information to us Also thanks to those at DaimlerChrysler and Cummins that provided their insight Is the grass greener on the other side We hope the TSB and Recall information will help you in your purchase ownership of the Dodge Cummins Turbo Diesel truck We choose to think that answers and solutions are much better than wonderment Happy Motoring A Publication of the TURBO DIESEL REGISTER MOST COMMON PROBLEMS The Most Common Problems title is certain to catch your attention Rightfully so we chose the brazen title to serve a purpose As a prospective owner or as the new owner of a used Turbo Diesel you need to be aware of the problems that are inherent with the truck you are considering or have recently purchased Although some will dwell on the proble
54. may read full until the vehicle travels over a bump in the road and then the gauge operates normally This condition may be caused by the float in the fuel pump module sticking and may be difficult to diagnose Perform the repair procedure new fuel pump module if the customer s concern matches the description identified in the Symptom Condition 08 43 99 98 99 BR Central timer module software update when a wiper module is replaced 12 17 99 This bulletin applies to vehicles equipped with remote keyless entry Due to a design change in MOPAR replacement wiper modules the central timing module must be updated with new software in order to allow the wiper module to function properly The outlined repair procedure must be performed any time the wiper module is replaced 08 44 99 99 00 BR Intermittent speaker operation static 12 31 99 This bulletin applies to vehicles equipped with the Infinity sound system sales codes RBR RBN and RAZ built before October 1 1999 The condition is intermittent operation static that may occur in any or all speakers The bulletin describes the proper repair CATEGORY 9 ENGINE TSB MODELS SUBJECT DESCRIPTION 09 04 99 98 99 BR Hard to diagnose noise coming from the engine turbocharger area 07 16 99 This bulletin applies to vehicles equipped with a Cummins 5 9L 24V diesel engine built prior to engine serial number ESN 56587424 The ESN is located on the engine data plate which
55. number of plastic covers are being replaced due to cracks Further analysis has revealed that the cracks may be caused by improper cover removal procedures Do not use the square opening to remove or install the cover The fuel filter cover may crack To remove or install the fuel filter cover correctly only use the 1 1 8 hex head Use of a six point socket is preferred 14 03 00 98 01 BR Maintenance to the Water In Fuel sensor probes due to possible fuel contamination 04 14 00 The probes on the end of the Water In Fuel WIF sensor may become less effective at sensing the presence of water in the fuel if they are exposed to contaminated fuel Contaminant from the fuel may insulate the WIF sensor probes and inhibit the WIF lamp from illuminating when water is present Any time service is performed on the fuel filter or fuel filter housing the probes on the end of the Water In Fuel sensor should be cleaned Use a clean cloth to wipe the WIF probes of any contaminant CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS SUBJECT DESCRIPTION 18 015 00 98 01 BR Driveability enhancements for winter fuel use and for hard starts Rev A This bulletin applies to vehicles equipped with a 5 9L 24V diesel engine built between engine 12 21 00 serial numbers 56419738 to 56798357 with a date of manufacture of December 16 1997 to November 15 2000 The customer may complain of poor driveability when winter fuel is used to power the engi
56. owners GG Okay this is another of our favorite topics Many TDR members have added aftermarket fuel pumps to work in tandem with or in lieu of the existing factory pump The drawback to any aftermarket accessory is that the owner is now responsible for installation of the product special parts and tools to support the installation and parts necessary should the new and improved accessory fail Admittedly the original fuel transfer pump has been problematic However before would recommend going the aftermarket route would suggest the keep it simple stupid solution Purchase a spare Cummins transfer pump Yes the part number has been superseded numerous times the final kit number 3990082 The current price at a Cummins distributor is 160 Next read and copy and understand the previous article showing how to replace the fuel transfer pump By using the factory parts you ll not have to worry about special aftermarket parts that may not be available to complete the repair when the truck breaks down A Publication of the TURBO DIESEL REGISTER Better yet consider the 98 5 02 transfer pump relocation kit from Vulcan Performance and Geno s Garage that allows you to change out the transfer pump in five minutes or less Read more about this kit on page 72 Customer What should tell my friend with the 03 and newer HPCR engine GG The HPCR fuel system is entirely different First and foremost the fuel transfer
57. possible so can spend money on things that want went through the diagnostic steps as Joe G stated by finding and locating the large three wire connector between the master cylinder and the engine and disconnected the solenoid from the wiring harness The black wire with the trace is the ground and the white wire is the hot to the pull up coil power You will need a 10 gauge wire for your test leads Apply the ground test wire to the black wire in the connector and 12 volts to the white wire The solenoid should pull up If it does not disconnect the linkage and try it again If the solenoid works the problem is most likely the relay but if it does not move then it is the solenoid A Publication of the TURBO DIESEL REGISTER My local Dodge dealer quoted me 450 for the part my local Cummins distributor quoted 285 decided to call my friend Randy at Dave s Diesel 800 343 73580 Dave s Diesel had one in stock for 265 less an additional 10 TDR member discount decided couldn t beat that The new kit comes complete with new solenoid and all new brackets and heavy duty hardware To remove the old solenoid start by disconnecting the wiring harness Then unbolt the two 8mm bolts that hold the solenoid in place and remove the clip that holds the solenoid to the linkage Next remove the three 8mm bolts that hold the mounting bracket to the governor housing Finally remove the old shutoff lever The new kit replaces t
58. pump Yes we ve all been told by Dodge and Cummins that the 03 transfer pump redesign is better than the old 98 5 to 02 pump but wanted to be prepared Guess what John Holmes wasn t joking You cannot buy the engine mounted 03 05 transfer pump from Dodge The old inventory has been scrapped out Believe me on this l tried to purchase 1150 units through Geno s Garage and was told about the scrap decision just prior to press time The part number 5093135AA has been superseded to the module in the fuel tank kit 68003869AA or 68003870AA at a price of about 375 Labor to remove the fuel tank and install the kit m guessing 400 No problem With my engine serial number in hand called my Cummins distributor Long story short same answer you cannot purchase the engine mounted fuel transfer pump from Cummins Their part number3957922 is superseded by a 95 conversion kit that is simply the seals washers screws fittings and hose that go with the relocation of a pump into the fuel tank The old 3957922 was priced fairly at about 150 Call me cheap Call me apprehensive but the claims that the 05 and newer pump in the tank is the greatest thing since sliced bread have not been substantiated by Father Time Call me lazy Call me incompetent do not want to drop my fuel tank to install the in tank kit So where can find the obsolete 3957922 If not the 395722 what other options do have F
59. pump is of a different design than the fuel transfer pump on the 24 valve engine Although we are early in the 03 and 04 engine s life cycle there are not reports of widespread problems with this newly designed transfer pump For 05 the transfer pump has been moved to a unit located in the fuel tank where the pump pushes fuel to the engine rather than pulling fuel from the tank On the HPCR engine the fuel is pressurized by a gear pump and loss of fuel pressure from the transfer pump does not equal an expensive fuel injection system failure The gear pump is not fully capable of pulling fuel from the tank so should a transfer pump fail the worst scenario is that the truck does not start due to loss of fuel prime Should you spend money on a gauge to tell you that the truck is not starting Customer Is there enough pressure to support higher horsepower settings with the 03 07 s fuel transfer pump GG In Issue 47 page 60 Technical Topics authors Doug Leno and Joe Donnelly had this to say about the HPCR fuel system It is not the purpose of this article to repeat the multitude of experiments showing the limitations of the stock lift pump and low pressure fuel system This series of tests was done simply to validate that the stock fuel system is sufficient for power enhancements delivered by the boxes we tested 100 horsepower and below We found no stumbling hesitation or other performance problems using any o
60. repair procedure covers If the audio drops out when the vehicle is moved from a cold to a warm or humid environment the reason is that condensation builds up across the audio amplifier circuitry causing the amplifier to shut down Typically cycling the ignition switch off and on will restore the audio output If the problem persists the correct repair procedure is to apply tape over the row of slots on the left hand side of the radio s top cover 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 e When the transmitter is pressed twice for start the vehicle horn will chirp once but the vehicle engine will not start e When the transmitter is pressed twice for start the vehicle horn will chirp twice indicating a problem with the remote start system and the vehicle engine will not start e When the transmitter is pressed twice for start the vehicle will chirp once the engine will start and then turn off The technician may not be able to verify the symptom s because it may be an intermittent condition The corrective action involves replacing the hood switch for the remote starting system 02 06 DR Radio communication equipment installation recommendations This information only bulletin gives the dealership technician some guidelines for the installation of two wa
61. staff at Geno s was solicited to purchase the Carter division of Federal Mogul F74213 or FP Diesel part number 3990105 fuel transfer pump assembly with wiring harness from a diesel injection shop Interesting how the 3990105 number matches the number sold by Cummins Furthermore Delphi is offering a fuel transfer pump part number FP923 at other diesel injection shops The Delphi FP923 box was opened and there was not a wiring harness included in their kit If my memory is correct the wiring harness is needed on 98 5 to 99 trucks as the early pumps had the harness pigtail protruding from the pump Without the harness extension the wires would be too short and not reach the replacement part So it looks like availability of a transfer pump for 98 5 02 will not be a problem However availability of a replacement pump for 03 04 5 owners is a major problem Page 74 has the details One last item to consider the devil you know is preferable to the devil you don t know None of the TDR audience knows how good or bad the 05 fuel transfer pump will be There is not yet enough time on the clock Nor do we know the symptoms of impending failure Nor do we know the high low and mid point performance in psi of the 05 pump Enough said As a side note Geno s Garage has chosen not to sell the fuel transfer pumps Although it would be no fault of the retail outlet that you may purchase the pump from th
62. sure it has been well maintained You surely don t want to buy a lemon when an engine can cost upwards of 7 000 a new transmission can cost upwards of 3 500 and a P 7100 rebuilt injection pump can cost you 1 400 Here are some buying tips to help you find just the right one for you Keep in mind that this is likely the second largest purchase you ll ever make second only to a home Some folks spend more on their transportation in their lifetime than they spend on housing While you may live in one place your entire life the average owner trades vehicles once every five years Every dollar saved on the purchase price of either a home or a vehicle will also save on interest dollars paid back if you are getting a loan So a dollar saved may actually amount to as much as 1 25 over the life of the loan Inform Yourself Before you ever set foot on a dealer lot or peruse the want ads take the time to familiarize yourself with the various models and options offered by the manufacturer and see how they match your intended use Narrow your search down to those models and model years which fit your budget and which will do the intended job Select only those models with the options you want Make a list of specifications keep it with you during your search and keep to your list For example if you determine you want a truck for hauling and towing but want an extended cab model with SLT interior do the research to find which model
63. temporary cure for the clunk A replacement steering shaft coupler is a long term solution In 4x4 models a clunk similar to that found in two wheel drive trucks may be caused by faulty track bar bushings or worn front suspension grease joints Groaning and other front suspension noises on 4x4 models built prior to 1994 can sometimes be traced to the universal joints at the outboard axle ends of 4x4 models A simple test is to engage the manual locking hubs and drive the vehicle If the noise disappears replace one or both joints On 4x4 models a front end shimmy may be caused by a worn steering stabilizer unit This horizontally mounted shock absorber should be periodically replaced as a wear out item This problem appears more frequently on trucks equipped with aftermarket tires and rims of a larger than standard size During servicing don t forget to check the fluid level in the power steering pump It is located low on the driver s side of the engine near the front in a location covered by hoses and wires 21 TRANSMISSIONS The cooling lines for automatic transmissions can have a point of close contact with each other where they cross near the bellhousing A piece of convoluted loom or rubber hose placed on one of the lines will prevent chafing and wearing through of the metal tubing All trucks built prior to 1998 5 and equipped with the NV 4500 five speed manual transmission have a problem with fifth
64. 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 A Publication of the TURBO DIESEL REGISTER 45 TSBs Issued During 98 CATEGORY 5 BRAKES TSB MODELS SUBJECT DESCRIPTION 05 04 98 97 99 BR Height sensing proportioning valve removal 6 12 98 This procedure should only be performed on 2500 series 4x4 vehicles that are continuously operated at 75 or greater GVW and have had their rear suspension altered The bulletin describes a procedure the dealer should follow in the removal of a rear height sensing proportioning valve Removal of the proportioning valve should help prolong front brake life CATEGORY 6 CLUTCH TSB MODELS SUBJECT DESCRIPTION 06 01 98 97 98 BR Release fork orientation 6 19 98 This bulletin applies to vehicles equipped with an NV4500 manual transmission and either the 8 0L gas engine or the 5 9L Cummins diesel engine The bulletin covers the proper installation of the clutch release fork CATEGORY 7 COOLING TSB MODELS SUBJECT DESCRIPTION 07 08 98 98 99 BR Diesel engine overheating 12 11 98 This information applies to vehicles equipped with a 24 valve Cummins 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
65. the Cummins engine At the time knew the Turbo Diesel Register would work also knew it would be a lot of hard work with an up front monetary investment and the commitment to publish the magazine Positive discussions with other club register publishers and an unofficial good luck or two from the manufacturers and well was still hesitant Back to the all important concerns time money and writing skills Time In the initial two career days it was nothing to stay up until 2 00 a m Money What the heck we took out a second mortgage And writing skills You ve heard the saying if it is to be it is up to me Thus we started the TDR way back in the summer of 1993 Robert Patton TDR Editor PS We hope you ll learn something from the following collection of tips and Dodge technical data Please realize this booklet is just the tip of the iceberg The TDR and its members provide a wealth of information How to join Please fill out and mail the order form below or register on line at www turbodieselregister com Join Us Today Name An annual subscription to the Address Turbo Dlesel Register is 35 00 ee City Please complete this subscription form and enclose it in an envelope along with your check or money Phone Home order payable to Work __ TURBO DIESEL REGISTER 1150 Samples Industrial Drive Truck Year Cumming Georgia 30041 770 844 1600 LI Payment Enclosed INFORMATION SUBSCRIPTION LINE LI
66. transmissions 245 HP 505 ft lbs torque HO engine for six speed manual transmission only Transmissions Five speed manual NV4500HD 5th overdrive Six speed manual NV5600 6th overdrive available only with the HO engine Four speed automatic 47RE 4th overdrive with locking converter Maximum Tow Ratings 2500 regular cab and quad cab 4x2 and 4x4 both manual transmissions both axle ratios 20 000 GCWR 3500 regular cab and quad cab 4x2 and 4x4 both manual transmissions both axle ratios 20 000 GCWR Exception 3500 4x2 and 4x4 six speed manual with 4 10 axle is rated at 21 500 GCWR 2500 and 3500 regular cab and quad cab 4x2 and 4x4 with automatic transmissions are rated 3 54 axle 16 000 GCWR 4 10 18 000 GCWR Note Maximum permissible trailer weight will vary by model and options Highest trailer weight rating is for a 3500 regular cab 4x2 six speed 4 10 axle 15 150 pounds Lowest trailer weight rating is for a 3500 quad cab 4x4 automatic 3 54 axle 9 000 pounds Cab Chassis Models Available in regular cab only 2500 is 8 800 GVWR 56 C A dimension 3500 is 11 000 GVWR and is available in 60 and 84 C A dimensions Tow ratings are same as above with maximum for 3500 six speed 4 10 axle of 21 500 GCWR Comments The six speed transmission remains on back order due to high demand New disc brake rear axle and standard 4 wheel ABS greatly enhances stopping ability on 01 5 trucks All truck functions are
67. will have no warranty from a manufacturer to fall back on in case of a problem Therefore you must be much more careful in inspecting your intended purchase The benefits to the used truck purchase the vehicle cost is less than new used trucks typically have had the new vehicle bugs fixed and they represent greater value for the dollar since the initial depreciation has already been taken by the first owner Awhole market has sprung up in the last few years for used Dodge Cummins Turbo Diesel trucks fueled in part by the high cost of a new one and by the fact that even trucks with high mileage have lots of life left in them due to the legendary reliability and durability of the Cummins diesel This has had a side benefit in that used Dodge Cummins trucks have retained a greater percentage of their resale value than the average for all diesel trucks and they command high prices on used vehicle lots This means you may pay more for your truck but will get more for it when you eventually become a seller Awell maintained truck with high mileage should not be disregarded as a good value since with good regular maintenance these trucks can reliably run half a million miles and more Vehicle purchasing can be divided into two parts One is buying the metal and the other is buying the money used for the purchase Your goal as a used truck purchaser is to get both parts right How do you select just the right truck and how do you make
68. will stop Final notes from the voice of experience had a heck of a time correcting my no start problem With both new relay and new solenoid laid out on top of the engine the solenoid did not want to pull up proceeded to un wire my hidden anti theft switch Issue 26 page 17 but that did not help After much frustration the solution presented itself the solenoid needed a little bit of pretension and it would pull up every time As it is installed there is pre tension in the linkage but there wasn t any with the solenoid laid out on top of the engine Jeez 108 Fuel Transfer Pumps Revisited The following article is from Issue 56 of the Turbo Diesel Register It was written in May of 07 by TDR Editor Robert Patton As the deadline for Issue 56 was fast approaching called TDR writer Jim Anderson Jim is the point guy for miscellaneous e mail and phone inquiries that come into the TDR asked Hey Jim what s on the minds of those that you are corresponding with His response It seems that problems with the Third Generation trucks vary There is not a common complaint that needs to be addressed This is good news for the Third Generation crowd Jim continued However with the used truck purchase of 98 5 02 vehicles the education about fuel transfer pumps is an endless task responded Ouch know what you mean Perhaps should emulate the country music singer David Allen Coe s eff
69. window 3 30 07 1500 2500 3500 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 02 07 Trailer Towing Mirror New mirror glass locking tab new removal procedure 04 13 07 DR DH D1 DC 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 mirror glass This bulletin involves a discussion regarding new removal procedure when replacing the mirror glass on a trailer tow mirror 23 028 07 06 07 DR DH D1 Buzz like sound from front door speaker area when radio is on Rev A 1500 2500 3500 The sound in question will come from the interior door trim panel in the area where the radio 7 20 07 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
70. wire often become corroded because of battery acid If so slip off the terminal and crimp on a new one The key to this diagnosis is the use of a cheap twelve volt test light Disconnect the fuel shutdown solenoid There are three leads in the wiring harness hot start ground and hot run When the connection at the battery is poor the test light will probably glow dimly when connected to the start pin of the wiring harness If your fuel shutdown solenoid is bad usually the start circuit is the one that has burned out If you turn the key on and pull up the fuel lever on the P7100 injection pump and the lever stays up the start circuit is bad or the solenoid is bad Cummins offers a newly designed solenoid that is much larger than the original that came on our Turbo Diesels and it comes with a much thicker mounting bracket Otherwise it will fit right onto the pump and its wiring harness plugs right into the Dodge harness The Cummins part number is 3800723 but be prepared for the cost about 278 Joe Donnelly TDR Writer MORE NO START SOLENOID REPLACEMENT In Issue 36 on page 36 Joe G Eureka CA discusses the method of checking the fuel shut off solenoid on the 94 thru 98 12 valve engines The editor made note to check your local Radio Shack for generic relays at a substantial cost savings But what do you do if the problem ends up being the fuel shut off solenoid itself like everyone else try to save as much money as
71. 0 GCWR Cab Chassis Models Not offered by the factory Howeve r commercial owners could order a box delete option Comments The 2004 model year was an exciting one for Dodge Cummins fans At year end the bragging rights to the most powerful diesel engine belonged to Ram owners with an engine certification of 325 HP 610 ft lbs torque It is interesting to watch as the horsepower race continues 2005 Turbo Diesel What is New Polished aluminum wheel replaces the painted aluminum sheel on 2500 3500 SRW models Optional on the Quad Cab are a power sunroof and satellite radio The Cummins 325 600 engine was voted one of the 10 Best Engines by Ward s Models Available 2500HD as standard cab quad cab short bed long bed 4x2 and 4x4 3500HD same as above The dual wheel 3500 is not offered with a short box Engine Ratings For 2005 the only rating offered is 325 HP and 610 ft lbs torque The engine is 50 state approved Transmissions Throughout the 2005 model year the New Venture NV5600 six speed manual was replaced by a Mercedes Benz designed G56 six speed manual transmission The reason for the change New Venture Gear was a joint venture company between DaimlerChrysler and GM In December of 2002 the partnership was disolved and New Venture was is wholly owned by GM The ratios of the NV5600 versus the G56 are shown below 1 2 3 4 5 6 R G56 6 29 348 2 10 1 38 1 0 79 5 74 NV5600 5 63 3 38 2 04 1 3
72. 004 Turbo Diesel also 2004 5 models What is New See 2003 model for description of new body and frame Minor trim and color changes 2004 model engine ratings and transmission choices are different for California Maine Massachusetts New York and Vermont These states were given the 235 HP 460 ft lbs engine only At mid year the 2004 5 engine with 325 HP and 600 ft lbs torque is released With it mid year introduction this engine is now the only engine offered 50 state certified Five speed manual transmission is not offered in 2004 5 models with 325 600 engine 2004 5 model is offered with uprated 48RE automatic transmission 3500 Quad Cab short bed now offered 7 70 powertrain warranty 7 100 000 Cummins engine warranty Models Available 2500HD as standard cab quad cab short bed long bed 4x2 and 4x4 3500HD same as above The dual wheel 3500 is not offered with a short box Engine Ratings The 2004 engine is 305 HP and 505 ft lbs and is available with six speed manual and 48RE automatic The states of CA ME MA NY VT are only offered the 235 HP 460 ft lbs engine for the first half of the year The 2004 5 engine is 325 HP and 600 ft lbs torque as standard with no optional engine Offered only with six speed manual or 48RE automatic Transmissions Early 2004 models for California Maine Massachusetts New York and Vermont five speed manual NV4500HD 5th overdrive All other states six speed manual NV
73. 07 06 08 Exterior Lamp lens fogging 08 08 07 DC DM DR DH D1 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 08 DR DH D1 Tailgate retaining cables appear to be of unequal lengths 5 10 08 1500 2500 3500 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 an appeara
74. 07 trucks when you open the fuel filter drain valve there is only a trickle of fuel Instructions in the Mopar filter box will tell you to drain only about eight ounces You ll be lucky if that much drains out Remove the water in fuel WIF sensor electrical connector from the bottom of the filter s plastic cartridge The tang on the connector wires is pushed out and the connector wires and female socket can then be pulled downward In shadetree fashion cut the tang so that the connector will be easier to remove in the future I ll let you debate the merits of tang cutting As mentioned in Issue 59 page 42 the fuel filter is buried under a myriad of electrical wires electrical relays and cables The fuel filter is next to impossible to access p Hii x yin Whig pasadi H naaa KTT hys I tried to access the filter from above no way An accepted field service practice on 4x4 trucks is to hug the front tire and come in from the side in between the gap in the plastic wheel well liner and the frame Two wheel drive guys need to remove the 8mm screws that hold the fender wheel well liner in place and drop the liner out of position For the truck s initial fuel filter service chose the under the vehicle service technique and a strap wrench to remove the filter wish had known about the Harvey Barlow technique page 40 Subsequent fuel filter changes can be done from above if you take the time to move the afor
75. 1 04 96 96 BR Transmission will not upshift following a 3 2 downshift 3 15 96 Under certain conditions the transmission will not upshift following a 3 2 downshift In this condition the engine will continue to operate at maximum governor speed in second gear until the throttle is reduced The condition only occurs if the overdrive is off The repair involves reprogramming the powertrain control module with new software 21 13 96 96 BR Transfer case shifter buzz or clatter 9 20 96 4x4 A buzz or clatter may be heard from the 4x4 shifter at an engine speed of approximately 2000 rpm The repair involves the addition of an insulating plastic gate liner to the transfer case shifter Quick connect removal and reconnect procedure 21 15 96 95 97 BR The information only bulletin describes the repair procedure for removal reconnect of the 11 8 96 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 94 96 BR Replacement cargo box information 1 5 96 This information bulletin list the revised part numbers for the 6 5 ft and 8 0 ft cargo box with a reinforced front box floor 23 02 96 94 96 BR Creak or tick noise from right side instrument panel 1 19 96 The noise can be reproduced by pushing on the instrument panel at the shelf above the glove box door The repair involves the removal of a 3 10 riv
76. 12 18 08 99 98 99 BR Improved speed control system sensitivity to set speed 04 30 99 Some customers may complain that their vehicle speed control system may be too busy or drift more than 2 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 99 BR Common diagnostic trouble codes caused by an open fuse 05 21 99 Analysis has revealed an issue with repeated repairs for the same Diagnostic Trouble Code DTC The DTC may be due to an overlooked open circuit used to power the component in question In most instances either the circuit fuse has been erroneously removed or the fuse itself is open blown The component in question and its circuit are often protected by two fuses It is usually the lower amperage fuse that is either missing or open The lower amperage fuse is positioned electrically in the circuit between the component in question and either a relay or the ignition switch The lower amperage fuse will be located either in the underhood Power Distribution Cente
77. 18 03 03 DR 6 13 03 Instrument panel whistle Awhistling sound may be present coming form 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 CATEGORY 24 HEATING amp A C TSB MODELS SUBJECT DESCRIPTION 24 009 02 All Chrysler group A C system leak detection 10 28 02 products using Vehicles from the factory no longer have leak detection dye in the A C system To determine the R 134A refrigerant source of a R 134a leak a leak tracer dye has to be injected into the A C system 24 003 03 90 04 A C system additives 5 23 03 All Chrysler group The use of A C system sealers may result in damage to A C refrigerant recovery evacuation products 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 seale
78. 18 VEHICLE PERFORMANCE Continued Improvement to the Temperature Sensor Rationality Test to prevent possible false test failures and their following related diagnostic trouble codes DTC P0071 Inlet Air Temperature Sensor Rationality DTC P0111 Intake Air Temperature IAT Sensor Rationality DTC P0514 Battery Temperature Sensor Rationality e Additional water in fuel WIF warning added to indicate that the operator has had a WIF DTC P2269 and has continued to operate the vehicle in excess of 500 miles without draining the water from the fuel filter The following 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 07 DC Flash DTC P0471 Exhaust pressure sensor rationality on Cummins 6 7 liter Turbo Diesel 12 05 06 This bulletin applies to vehicles equipped with a 6 7 liter engine sales code ETJ built on or before October 05 2006 The vehicle operator may experience a malfunction indicator lamp MIL illumination due to diagnostic trouble code DTC P0471 exhaust pressure sensor rationality This bulletin involves selectively erasing and reprogramming the engine control module ECM Cummins with new software 18 001 07 06 07 DH D1 Flash check gauges lamp illum
79. 2 AF4555M 4429107 05016547AA 4428308 70540 89 3834656 3932217 3865405 3097072 5080820 71530 FS1232 LF3349 LF3552 AF4555M 140 A Publication of the TURBO DIESEL REGISTER WHY ASK WHY LIOUIDS IN YOUR TRUCK By Robert Patton updated 7 08 Servicing a new and unfamiliar vehicle model for the first time can be frustrating As thumbed through the Volkswagen New Beetle diesel Owner s Manual there were many listings for lubricants that only showed the manufacturer s part numbers in this case those of Volkswagen Purchase of the Robert Bentley shop manual did not give any further insight Nor did a visit to the local VW parts counter unlock the mystery of the specification of the lubricants needed for routine maintenance Case in point what is the specification for and thus alternate read less expensive the lubricant needed for the five speed gearbox took the path less researched as there was not an easy answer and purchased 20 per liter the Volkswagen part number G005 000 oil for my gearbox vowed to get some answers to many of the other VW specific part numbers as they have a special number for all things liquid power steering what is G002 000 synthetic oil oil and antifreeze used in the vehicle The only thing easy was the DOT 4 brake fluid Thinking back had run into a similar situation with another foreign car once owned Anyone care to point me in the direction of a P
80. 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 A Publication of the TURBO DIESEL REGISTER CATEGORY 21 TRANSMISSION Continued 21 11 95 7 7195 21 04 94 3 4 94 21 10 94 5 27 94 21 17 94 9 16 94 21 18 94 9 30 94 21 24 94 12 2 94 21 25 94 12 23 94 21 23 93 9 3 93 21 39 93 12 31 93 21 18 92 11 30 92 21 11 91 21 05 90 2 26 90 21 14 90 5 7 90 21 12 89 5 1 89 96 BR trucks with Overdrive unavailable in extreme cold temperatures automatic The information only bulletin emphasizes a change to the PCM for 1996 For 96 in ammbient transmission temperatures of 5 F 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 ov
81. 28 99 08 22 99 07 02 99 08 28 99 08 20 99 08 32 99 10 01 99 08 37 99 11 12 99 08 39 99 12 10 99 MODELS SUBJECT DESCRIPTION 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 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 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
82. 35 2700 460 1400 8412 5 Manual 3 23 103 5 250 2900 460 1400 8212 48RE Auto EPA Non Catalyst 23 5 9 HPCR 8226 5 Manual 23 8228 6 Manual 26 305 2900 555 1400 8213 48RE Auto 26 8412 48RE Auto CARB Catalyst equipped 23 235 2700 460 1400 04 8412 6 Manual i 23 5 9 HPCR 8213 48RE Auto EPA Non Catalyst 26 305 2900 555 1400 8228 6 Manual i 26 8350 6 Manual EPA Catalyst equipped 30 a 325 2900 600 1600 eo i A f Sau 5 9 HPCR 8346 48RE Auto EPA 30 8347 CARB 30 8423 6 Manual EPA Catalyst equipped 30 hes 325 2900 610 1600 soil f CARE i a 5 9 HPCR 8421 48RE Auto EPA 30 8422 i CARB j 30 8348 6 Manual EPA Catalyst equipped 30 ue 325 2900 610 1600 eves l PADE l 5 9 HPCR 8344 48RE Auto EPA i 30 8345 CARB i 30 1091 6 Manual EPA Catalyst equipped 30 7 325 2900 610 1600 ae f OARE ste 5 9 HPCR 1000 48RE Auto EPA 30 1083 i CARB 30 8233 6 Manual EPA 28 610 1600 07 5 8234 CARB 28 350 3000 6 7 HPCR 8230 68RFE Auto EPA 28 650 1600 8231 i CARB 28 8232 6 Manual EPA 26 07 5 1264 CARB 26 6 7L Cab 305 2900 610 1600 Chassis 2885 Aisin Auto EPA 26 1257 i CARB 26 A Publication of the TURBO DIESEL REGISTER Boost Model Year HP RPM Torque RPM CPL Transmission Comments Specification 08 610 1600 1489 6 Manual All Certifications 28
83. 4 07 48RE Transmission 1 2 shift hunt at light throttle 5 24 07 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 21 019 07 07 08 DH D1 68RFE transmission harsh coastdown shift and or harsh 2 3 upshift 11 14 07 2500 3500 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 coastdown shift This bulletin involves selectively erasing and reprogramming the transmission control module TCM with new software 90 A Publication of the TURBO DIESEL REGIS
84. 500 vehicles equipped with 6 7 liter Cummins Turbo Diesel engine sales code ETJ built on or before June 11 2007 This bulletin supersedes technical service bulletin 18 033 07 Rev A dated June 12 2007 The vehicle operator and or technician may experience one or more of the following conditions and or enhancements e The technician may not be able to reprogram flash the PCM with new application software The vehicle may fail an emission inspection maintenance I M test because two or more on aboard diagnostic OBD monitors report that they are not ready for testing This condition may cause the customer vehicle to fail an emissions I M test The following is a list of OBD Monitors that may report as not 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 DTC s P1451 Diesel Particulate Filter System performance P2463 Diesel Particulate Filter Soot Accumulation P242F Diesel Particulate Filter Restriction Ash Accumulation e The vehicle operator may experience a MIL illumination
85. 5600HD 6 overdrive Four speed automatic 48RE 4th overdrive with revised torque converter lockup clutch programming Differential Ratios Offered 3 73 and 4 10 to 1 Maximum Tow Ratings 2500 rugular cab and quad cab 4x2 and 4x4 235 HP 460 ft lbs torque engine in the states of California Maine Massachusetts New York and Vermont five speed 3 73 differential 18 000 GCWR five speed 4 10 differential 20 000 GCWR 48RE automatic 3 73 differential 17 0000 GCWR 48RE automatic 4 10 differential 19 000 GCWR All other states with the 305 HP 505 ft lbs engine or the 2004 5 325 HP 600 ft lbs engine all states approved were shown to have a 20 000 GCWR regardless of transmission or axle ratio 3500 single or dual wheels regular cab and quad cab 4x2 and 4x4 235 HP 460 ft lbs torque engine in the states of California Maine Massachusetts New York and Vermont five speed 3 73 differential 18 000 GCWR five speed 4 10 differential 20 000 GCWR 48RE automatic 3 73 differential 17 000 GCWR 48RE automatic 4 10 differential 19 000 GCWR All other states with the 305 HP 505 ft lbs engine or the 2004 5 325HP 600 ft lbs engine all states approved with either an automatic transmission or six speed 3 73 differential 21 000 GCWR 4 10 differential 23 000 GCWR Summary Varies by model and options Maximum is quad cab or standard cab 4x2 six speed manual 4 10 axle ratio 4x2 23 00
86. 7 RE RH automatic transmissions In this case logic prevails if 3 is good then 4 is better This information was verified by D C s customer advocate personnel If you have any doubts about the correct transmission fluid consult your Owner s Manual Five Speed NV4500 Manual Transmission Change every 30 50 thousand miles depending on load Use 75W 90 GL 4 or 80W 90 GL 4 rated synthetic oil Often members will ask about the GL 4 rated Castrol synthetic gear lubricant 75W 90 If the GL 4 classification is good shouldn t a GL 5 rated lubricant be better In the case of the NV4500 gearbox not necessarily so The GL 5 oil uses twice the amount of sulfur phosphorous additive package as GL 4 At high temperatures the phosphorous plates out and reduces the coefficient of friction of the synchronizer rings New Venture Gear has seen this on shift stand tests Since there s twice as much of it there s more of a detrimental effect compared to GL 4 Although it does not affect the NV4500 the additional sulphur content of GL 5 attacks brass Six Speed NV5600 Manual Transmission This transmission is filled with manual transmission fluid at the factory This fluid does not require periodic changing If it is necessary to add or change the fluid in this transmission use Mopar manual transmission fluid Mopar P N 4874464 or Texaco 1874 These are the only lubricants recommended for use in the NV 5600 transmission Axle oil Cha
87. 9 1 0 73 5 63 The automatic transmission remained the 48RE Differential Ratios Offered 3 73 and 4 10 to 1 A Publication of the TURBO DIESEL REGISTER Maximum Tow Ratings In the 2005 Ram Truck brochure the factory simply lists payload and towing weights With the previous GCWR numbers we ve used the reader knows that the maximum trailer weight plus weight of the truck equals the GCWR Effectively the heavier the truck is the ess the trailer can weigh to not exceed the GCWR The 2005 brochure does not list truck weight or the TDR would do the math inorder to present consistant data to you The data we have is presented below 2005 Payload and Towing Maximums Payload Trailer Weight 2500 Regular Cab 4x2 2740 13 600 Regular Cab 4x4 2340 13 200 Quad Cab 4x2 2520 13 350 Quad Cab 4x4 2230 13 100 3500 Regular Cab 4x2 4910 16 250 Regular Cab 4x4 5200 15 850 Quad Cab 4x2 4550 16 300 Quad Cab 4x4 4840 15 950 Cab Chassis Models Not offered by the factory However commercial owners could order a box delete option 2006 Turbo Diesel What is New In the fall of 2005 Dodge introduces the Mega Cab as a 2006 model Although it has four doors the current Quad Cab has always been seen by Dodge as an extended cab model As its entry into the crew cab marketplace the Dodge Mega Cab boastfully features the following largest best in class attributes Largest longest cab 143 2 cubic feet 111 1 inches long
88. 94 BR 91 93 AD 94 BR All trucks 89 91 AD 91 AD CATEGORY 9 Radio lock up The bulletin applies to AM FM Stereo RAL or AM FM stereo cassette RAS radios If the buttons and controls do not function the condition is caused by a programming error The condition is corrected by following the operational sequence outlined in the TSB Erratic coolant temperature gauge reading The cooling system on the Cummins diesel engine equipped vehicles provide for capacity and protection at high GCWR THe large capacity can cause slower than normal warm up Also temperature gauge reading fluctuations are normal Fuel gauge innaccuracy Too much reserve fuel in the tank when the gauge indicates empty may be the fault of an incorrect sending unit The repair involves a wiring harness and sending unit change Service procedure for the stop light switch connector An information only bulletin showing the disconnect procedure of the stop light switch Trailer tow wiring installation The information only bulletin gives guidelines for proper wiring of trailer tow wiring packages Speedometer reading fluctuates and or the speed control disengages The condition may be caused by spread female connectors at the 2 way distance sensor connector Inspect and replace as necessary Fuel reads low when fuel tank is full If fuel gauge does not read full after filling the fuel tank the problem may be an incorrectly cal
89. 997 Bonneville speed weeks of 141 256 mph TDR Issue 15 page 44 Second Generation 1994 Turbo Diesel What is New Introduction of the current truck platform Everything is new Models offered 2500 and 3500 two wheel drive four wheel drive standard cab long bed only Cab Rather revolutionary styling which has since been emulated by other truck manufacturers Styling changes included protruding grille and hood Grille is attached to hood and raises with hood for improved underhood access Cab has aerodynamically correct shape Offered only as a standard cab long bed truck and as a cab chassis model Two trim levels ST in vinyl and SLT in cloth Cab features include redesigned dash with full gauges featuring numbered graduations All major cab controls designed to be operated by a gloved hand An optional bench seat with a 40 20 40 center console split is offered with the center console capable of containing a laptop computer and cellular phone Cab is attached to frame using resilient rubber donut cushions Large sloped tinted windshield with parallel wipers driver side air bag open storage nook in right side of dash for future addition of passenger side air bag cruise control buttons on steering wheel and reclining driver seat Chassis All new frames with combinations of boxed and C channeled sections for greater rigidity Front suspension consists of independent coil springs with 4500 pound capacity front axle
90. A ME MA are only offered the 235 HP 460 ft lbs engine 250 HP and 460 ft lbs torque for the 48RE automatic introduced mid year as an 03 5 and five speed manual transmission 305 HP and 555 ft lbs torque high output HO engine with six speed manual only Transmissions Five speed manual NV4500HD 5th overdrive only with standard engine Six speed manual NV5600HD 6th overdrive only with HO engine In the first half of the 2003 model year the four speed automatic 47RE 4th overdrive with locking converter only with standard engine In January of 2003 Dodge released the 48RE automatic transmission 4th overdrive with locking converter Maximum Tow Ratings 2500 regular cab and quad cab 4x2 and 4x4 five speed 250 hp engine 3 73 differential 19 000 GCWR 18 000 GCWR for the states of CA ME MA 4 10 differential 20 000 GCWR 2500 regular cab and quad cab 4x2 and 4x4 47RE automatic transmission 235 hp engine A Publication of the TURBO DIESEL REGISTER 3 73 differential 18 000 GCWR 17 000 GCWR for the states of CA ME MA 4 10 differential 20 000 GCWR 19 000 GCWR for the states of CA ME MA 2500 regular cab and quad cab 4x2 and 4x4 six speed or 48RE automatic transmission 3 73 or 4 10 differential High Output 305 hp engine 20 000 GCWR 3500 regular cab and quad cab 4x2 and 4x4 five speed 250 hp engine single or dual rear wheels 3 73 differential 19 000 GCWR 18 000 GCWR for the
91. Brother in law calls from the side of the expressway located in the less desirable side of town The truck will not run He has not read the TDR You have You start with the basics What happened It just quit running Did you just fuel up Nope Will it restart or is it completely dead It will run for a few seconds then it shuts off Okay open the hood and find the fuel filter Next bump the engine over and bring the key back to the run position Do you hear the buzz of the fuel transfer pump Ah okay did that and no buzz noise just some clicking noises By the way what s a fuel transfer pump Arrg Obviously brother in law missed the 12 page article in Issue 56 about fuel transfer pumps Since this part which is the Achilles heel of a fine Cummins engine can lead to a compromising and perhaps expensive engine down situation you ll want to have a plan of action Don t think that the fuel transfer pump problem won t happen to you or someone you know As you read in the Issue 56 article it is not likely to cause the 94 98 owners too much trouble as their fuel transfer pump is a mechanical unit that fails gradually The 98 5 02 owners you desperately need to have a plan of action There were about 450 000 trucks made in this series of 4 5 years For these owners nothing has changed in the past year You ll want to read reread Issue 56 The 03 04 5 owners Previously it was thou
92. CATEGORY 2 FRONT SUSPENSION TSB MODELS SUBJECT DESCRIPTION 02 03 97A 94 97 BR Rear of vehicle sits too low 8 29 97 This bulletin supersedes TSB 02 03 97 as there were part number errors in the previous bulletin The bulletin applies to 1500 series trucks rated at 6400 GVW and 2500 series trucks rated at 8800 GVW The bulletin discusses rear leaf springs and shock absorber availability that will increase the height of the vehicle when the vehicle is at maximum GVW The bulletin gives specific part numbers for various applications CATEGORY 5 BRAKES TSB MODELS SUBJECT DESCRIPTION 05 03 97 94 97 BR Chassis dynamics diagnosis 3 17 97 The bulletin supersedes TSB 05 10 96 as revisions have been made to torque specifications and procedures The bulletin summarizes different conditions that can cause a vehicle to move to the right or left when not controlled by the driver A lengthy test procedure is outlined to isolate the cause of vehicle drift 05 04 97 94 97 BR Accelerated brake lining wear front versus rear 3 28 97 2500 3500 series This bulletin supersedes TSB 05 02 96A as the bulletin incorporates the use of revised brake linings for trucks with 80mm calipers typically found on 2500 4x2 trucks The bulletin discusses wear conditions repair procedures part numbers and rear brake adjustment procedures 05 07 97 98 BR Parking brake release handle does not fully return 9 22 97 The bulletin applies to truck
93. CT DESCRIPTION 08 25 95 94 95 BR Power mirror vibration associated with installation of bugscreen deflectors 6 9 95 The symptom is blurred images in the power mirrors The diagnostic procedure remove the bugscreen If vibration ceases the mirrors are ok Bugscreen deflectors are designed to disrupt airflow which can lead to mirror antenna vibration 08 24 95 94 95 BR Accessory frame ground jumper wire 9 30 95 The bulletin discusses a frame ground jumper wire from the battery negative to the frame bumper bracket be added if electrical accessories winch lights snow plow etc are added to the vehicle A Publication of the TURBO DIESEL REGISTER 25 CATEGORY 8 08 22 95 5 12 95 08 16 95 A 08 05 94 1 20 94 08 06 94 2 4 94 08 08 94 A 5 20 94 08 10 94 2 18 94 08 17 94 4 1194 08 29 94 6 24 94 08 33 94 7 15 94 08 41 94 8 5 94 08 64 94 11 4 94 08 65 94 11 4 94 08 05 93 2 8 93 08 07 93 A 3 19 93 26 94 96 BR 89 93 AD 94 96 BR 89 93 AD 94 BR 94 BR 94 BR 94 BR 94 BR 94 BR 91 93 AD 94 95 BR 94 95 BR 94 BR 93 AD 92 93 AD with four wheel drive ELECTRICAL Continued Installation of radio equipment The bulletin supersedes 08 31 94 7 15 94 and discusses the proper installation of communication equipment in Chrysler ve
94. Cab Chassis Models Discontinued However commercial owners could order a box delete option Comments This is the first full model year of production of rear disc brakes with standard four wheel antilock brakes A Publication of the TURBO DIESEL REGISTER Third Generation 2003 Turbo Diesel What is New All new body and cab interior layouts It is called Third Generation by Turbo Diesel enthusiast New full four door cab option with forward hinged rear doors is still called the Quad Cab New hydro formed boxed frame for greater rigidity New High Pressure Common Rail diesel engine fuel injection system eliminates distributor type fuel injection pump New engine meets tighter emission control standards while offering more power Driving axles are now supplied by American Axle in ratios of 3 73 and 4 10 to 1 The 4x2 models get new rack and pinion steering system while 4x4 models retain recirculating ball system of previous models All models use 17 inch wheels and tires The 3500 model is available with either single or dual rear wheels Models Available 2500HD as standard cab quad cab full size rear doors short bed long bed 4x2 and 4x4 3500HD is available in single rear wheel and dual rear wheel versions Dual wheel version has higher weight and towing capacities Dual wheel version is not offered with a short box Engine Ratings 235 HP and 460 ft lbs torque for 47RE automatic The states of C
95. Cummins 3931476 Fleetguard FS19528 14 04 98 98 BR Accelerator pedal buzzing noise with cruise control engaged 5 8 98 This bulletin applies to vehicles equipped with the 5 9L 24 valve Cummins diesel engine If an audible buzz is coming from the accelerator pedal when the cruise control is engaged a road test diagnosis is described If necessary a re routing of the accelerator cable is described CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS SUBJECT DESCRIPTION 18 06 98 94 98 BR Hard starting diagnosis 2 27 98 This information applies to the 5 9L Cummins mechanically injected 12 valve diesel The discussion covers hard or no start diagnosis and repair 18 07 98 94 98 BR Effects of incorrect idle speed 2 27 98 This information applies to the 5 9L Cummins mechanically injected 12 valve diesel Incorrect idle adjustments either too high or low may cause many different customer concerns The bulletin gives a list of items that explain the condition symptoms associated with incorrect idle settings along with component checks and specifications to set it properly 8 A Publication of the TURBO DIESEL REGISTER CATEGORY 21 TRANSMISSION TSB MODELS SUBJECT DESCRIPTION 21 10 98 94 99 BR Loss of fifth gear Rev A This bulletin supersedes technical service bulletin 21 10 98 with an effective date of September 9 25 98 11 1998 This bulletin applies to vehicles equipped with a NV 4500 manual transmission
96. EGORY 5 BRAKES TSB MODELS SUBJECT DESCRIPTION 05 09 95B 94 95 BR Drift left or right under moderate or hard braking 9 22 95 All 4x4 and 3500 4x2 The symptom is a drift right or left during moderate to hard brake applications just short of antilock Club Chassis only operation The condition is more evident with worn brakes The steering wheel remains straight ahead truck drifts The repair is not to correct a condition where the steering wheel moves during the drift If steering wheel moves a brake system inspection according to the service manual is in order The repair involves installing shems between the wheel and 2500 hub bearing assemble 3500 hub extension as required 05 02 95 94 95 BR Front brake noise on trucks with 86 mm diameter caliper pistons 3 24 95 3500 4x4 4x2 The symptom is a squeal noise when applying the brakes for a normal stop The repair involves 2500 4x4 grinding or filing a chamfer on both ends of the front brake pads 05 03 94 94 BR Service manual revision for brake bleeding procedure on trucks equipped with ABS brakes 3 4 94 05 21 94 89 93 AD Premature brake wear on trucks with 12 brake drums 10 21 94 The bulletin involves replacement of the rear brake shoes linings with revised shoes 05 08 93 A 94 BR Pedal feel characteristics of ABS brakes is the subject of this information only bulletin 9 3 93 05 15 93 94 BR Brake pedal noise 11 1 93 The symptom
97. ENGINE TSB MODELS SUBJECT DESCRIPTION 09 02 00 99 00 BR A heavy oil or fuel like odor coming from the diesel engine compartment 02 18 00 This bulletin applies to vehicles equipped with a 5 9L diesel engine The problem is a heavy oil or fuel like odor coming from the engine compartment This condition may occur after the engine oil has been changed The odor appears to 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 00 BR Engine oil seepage past the oil fill cap on 5 9L 24V diesel engine 02 18 00 This bulletin applies to vehicles equipped with a 5 9L 24V diesel engine built before engine serial number 56664950 with a date of manufacture of December 8 j 1999 Oil seepage may be noticed in the area of the oil fill cap This may be due to paint overspray around the oil fill opening of the cylinder head valve cover The paint overspray may cause an uneven sealing surface The corrective action involves u
98. IESEL REGISTER 43 CATEGORY 22 WHEELS amp TIRES TSB 22 01 97 6 13 97 MODELS SUBJECT DESCRIPTION 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 23 22 97 4 4 97 23 25 97 5 2 97 23 27 97 5 9 97 23 39 97 6 27 97 23 61 97 11 28 97 23 67 97 12 6 97 23 68 97 12 19 97 MODELS SUBJECT DESCRIPTION 89 93 AD Difficult to clean light colored chalky residue from black plastic body components 94 97 BR The discussion covers difficult to clean light colored chalky residue from exterior plastic body components that are molded in black especially those that are textured such as door handles mirrors roof rack attachments etc Frequently this chalky residue is actually an accumulation of car wax road grime etc trapped in the plastic grain The correction is to clean the component with a soft bristle brush and mild detergent liquid dish soap until the residue is gone 94 97 BR Driver s side wiper blade contacts A Pillar This bulletin applies to vehicles built before Oct
99. IN position through March 23 1996 Lago Alberto M in the 11 VIN position through April 14 1996 Saltillo G in the 11 VIN position through April 14 1996 The repair involves installing a blower motor relay and overlay harness to remove the blower motor circuit from the ignition switch In addition the ignition switch and electrical connector must be inspected for damage and replaced if necessary Note to TDR subscribers the primary parts package for this repair does not include a replacement ignition switch assembly but rather provides a blower motor relay and overlay harness if necessary an ignition switch wiring pigtail clips screws washers etc to install the blower motor relay During the repair the ignition switch and associated connectors are to be inspected The technician is instructed to look for indications of melting or deformation specifically at terminals four and five Very few vehicles are expected to require ignition switch replacement Editor s note The title of the recall Ignition Switch Recall 875 leads one to conclude that the recall is to replace the ignition switch assembly As summarized from the dealer service instructions the recall has very little to do with the ignition switch but rather is focused on adding a relay to the blower motor circuit The moral of the story don t jump to conclusions based on the title of a memo and be sure additional trailer light
100. J locations 131 132 18 VEHICLE PERFORMANCE Interested in improving the highway fuel mileage of your Dodge Joe Kubina Aerodynamic Development Engineer at Chrysler Corp says removing or laying down the tailgate on your truck will not improve fuel mileage and in fact could worsen it It seems the Dodge body shape is designed to flow air properly across a closed tailgate to maximize highway fuel economy 21 TRANSMISSIONS Michigan TDR member Paul Refer wrote in to say his automatic transmission would not go into overdrive after a cold start in very cold weather The editor pointed to the Owner s Manual that says If the vehicle is started in ambient temperatures of 5 degrees F or below the overdrive will not turn on This protects the transmission from damage if the cooling system freezes Overdrive operation will resume when the ambient temperature has risen to approximately 2 degrees F If you tow or haul heavy loads with an automatic transmission a transmission temperature gauge is a must Reluctant to cut a hole in the oil pan to install the sensor Member John Holmes tested a gauge sender unit in which the sender is installed on the transmission oil dipstick Slick and it works Available as a kit from Geno s Garage Call 1 800 755 1715 When installing a new automatic transmission pan gasket or almost any other gasket that doesn t want to stay in place during the mating of the gasketed parts spread a
101. Safety Recall 970 part CANZ9700 Ref 34 p 44 If your truck has throttle but low power excessive smoke its quite possible that one or more of the rubber boots connecting the turbocharger and intercooler piping has slipped under its clamp allowing your turbocharger s pressurized air to leak Properly replace the boot under the clamp retighten the clamp and inspect the rest of the rubber boots of the system for holes in boots or slipping under clamps to restore full manifold boost pressure Glitch Can you say diet Fix No recall service bulletin or advisory has ever been published on this subject but some Ram owners found that the seat cushion collapses and the problem is common to all Second Generation trucks Repair options include an aftermarket seat or new replacement seat both of which may cost as much as the truck s Blue Book value at this point a local reupholstery shop or since the seats have springs at the bottom a home made remedy of restuffing for a few bucks Alternate fixes include new shock absorbers more weight in the bed or cutting back the calories Ref 35 p 14 Glitch It s very hard to stop No 4WD HVAC acting weird vintage 94 96 trucks Fix So what To paraphrase the immortal words of Commendatore Fanfani anybody can make a car go slow don t bother me with details about brakes Any time the brakes and HVAC act strangely simultaneously suspect the vacuum source Typically the p
102. Sensor APPS in an off idle position pedal depressed and the transmission is shifted into drive or reverse while the APPS remains in an off idle position pedal depressed causing the engine to remain at idle e Lack of power while towing or hauling a heavy load with the transmission in overdrive vehicles equipped with 47RE transmission The repair involves selectively erasing and reprogramming the Cummins CM845 engine control module ECM with new software 18 030 03 98 5 02 BE BR Generic Cummins engine control module ECM procedure 8 29 03 03 04 DR 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 ECM s will require programming utilizing the DRBIII and TechCONNECT 18 003 04 03 04 DR Poor A C performance slow fuel gauge response and diagnostic trouble codes PO341 and P1757 2 3 04 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 per
103. TER CATEGORY 22 WHEELS AND TIRES TSB MODELS SUBJECT DESCRIPTION 22 001 05 00 01 BR BE Chrome wheel care 12 1 05 02 06 DR This information only bulletin discusses chrome wheel care Chrome wheels should be cleaned regularly with mild soap and water or Mopar Car Wash Concentrate to maintain their luster and prevent corrosion Wash them with the same soap solution as the body of the vehicle Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels Any of the Do Not Use items listed below can damage or stain wheels and wheel trim e Wheel cleaners that contain hydrofluoric acid biflouride compounds sulfuric acid or phosphoric acid Any abrasive type cleaner Any abrasive cleaning pad such as steel wool or abrasive brush Any oven cleaner e Acar wash that has carbide tipped wheel cleaning brushes 22 005 06 03 07 Front end shimmy on 4x4 vehicles when traveling over rough surfaces in the road 10 07 06 DR DH D1 DC 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 pro
104. This information only bulletin discusses the use of supplements to the power steering fluid Do not use fluids or supplements that contain Teflon as they will cause a restriction at the filter in the power steering system The power steering fluid used in Chrysler Group vehicles is an engineered product The addition of any unapproved fluids or supplements can interfere with the proper function of the fluid and cause damage to the steering system To ensure the performance and durability of Chrysler Group steering systems use only Mopar Power Steering Fluid 4 ATF 4 automatic transmission fluid or equivalent MS 9602 in the power steering system 19 003 05 03 05 DR In and out movement in steering column 5 3 05 This bulletin applies to vehicles built after December 1 2003 If there is a small amount of movement in the steering column when pulling the steering wheel toward you while seated in the driver s seat the TSB outlines the proper repair procedure which involves the installation of a steering retainer kit to the steering column 88 A Publication of the TURBO DIESEL REGISTER CATEGORY 19 STEERING Continued 19 008 05 02 06 DR Revised power steering system bleeding procedures Rev A This bulletin supersedes service bulletin 19 008 05 dated October 26 2005 The bulletin 11 2 05 discussed that Mopar Power Steering fluid 4 or ATF 4 MS 9602 is to be used in the power steering system of DR vehicles No other po
105. Way We Were column and update projects and issues as we have more data This gives another opportunity to reemphasize the value of the TDR indexes that have been published in Issues 41 37 33 29 25 21 and 17 Also note the yearly Dodge Technical Service Bulletin summaries that are in this issue of the magazine The index and the TSB summaries that have appeared in Issue 38 34 30 26 22 and 18 are great tools to have in your toolbox Robert Patton TDR Staff 145
106. a seal leak The fix involves staking the pin covering the pin with a teardrop shaped washer placed under a nearby bolt or removing the pin altogether since it has already served its purpose in locating the housing during engine assembly Ref 40 p 56 and p 148 A picture showing an egg shaped washer that covers the dowel pin Glitch No cruise control crankshaft position sensor okay Fix On 89 to 98 5 12 valve trucks the cruise control can become inoperative due to battery acid corrosion from the driver side battery Replace the control unit after cleaning the area with a baking soda water solution to neutralize spilled battery acid Also inspect the battery tray above the solenoids for corrosion damage and repair as necessary Glitch Low power output on 24 valve engines Fix Clean replace the MAP Manifold Absolute Pressure sensor and or the AIT Air Intake Temperature sensor to restore power that is caused by false readings from these dirty sensors Dirty sensor tips or poor electrical connections at ostensibly weatherproof plugs render the sensors inoperative which causes restrictions in fueling 103 104 Glitch 94 98 12 valve P 7100 engine specific problems Fix The fuel return line rubber portion on the underside of the intake manifold in the area of the fuel filter boss tended to fail due to engine heat and to air getting into the fuel system Replacing the hose with a better quality hose th
107. above truck s 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 above 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 vehi
108. acket Then they bend around the bell housing where a short length of 3 8 rubber fuel line provides a fuel supply to the fuel heater line that extends behind the fuel filter Due to the age of the 12 valve truck careful inspection is necessary from the tank to the fuel heater strainer to ensure that there are no leaks in the fuel lines recall a discussion Issue 44 page 32 where Brandon Parks at Geno s Garage had a lengthy battle with a hard to start 97 12 valve truck After weeks of troubleshooting he did a close inspection of the metal fuel supply line comming from the tank as it turned upward by the firewall A pin hole caused by years of chafing was the problem A Publication of the TURBO DIESEL REGISTER The module has metal pipes exiting the top of the module supply and return and has hard plastic tubing coils that extend to the bottom of the module where a removable screen covers the pickup and return Most of them that I ve dissected have a one way check valve in the fuel pickup to assist in holding fuel prime Many members have noted that these lines sometimes chafe and develop a pinhole which allows for fuel aeration not a good thing The perforated tubing seems to have rubbed on a sharp edge or on the mounting hardware for the lower float we previously discussed The return also returns fuel to the bottom of the module above tank bottom about 1 4 This is preferable as it allows returned fuel to be release
109. ade 1 diesel fuel when ambient temperatures are below 0 C 32 F typically prevalent during the Winter months in Alaska Northwestern Canada and similar climates temperatures elsewhere This change will have no effect on performance during warm weather or when standard grade diesel fuels 1 or 2 are used Vehicles with 49 state certification can apply this calibration change if needed The calibration can be changed back to the original calibration if desired 66 A Publication of the TURBO DIESEL REGISTER CATEGORY 19 STEERING TSB MODELS SUBJECT DESCRIPTION 19 009 01 97 02 BE BR Driver airbag trim cover service 10 26 01 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 01 BR Overdrive disabled to improve transmission reliability during cold temperature operation 02 16 01 This bulletin a
110. amper aren t under the sensor when setting the air gap tighten and torque the mounting nuts to 18 ft Ibs and remove the feeler gauge 19 Reinstall the fan and fan support bracket along with the fan shroud The torque value for the four 10mm fan shroud bolts is 18 ft Ibs Once the fan is in place the fan shroud can be installed Again it is nice to have assistance as you carefully lower the fan fan support into place 20 Reinstall the windshield washer tank to the fan shroud 21 Reinstall the engine accessory drive belt according to the diagram on the front radiator support of your truck 22 Check around the engine compartment and make sure all tools and equipment are clear of any moving parts and test start the engine Check for any oil leaks and to make sure the engine drive belt is running straight Correct any oil leaks or drive belt problems before driving the truck Thanks to the folks at TST for allowing us to take excerpts from their detailed installation instructions Scott Kilby Robert Patton TST Products TDR Staff 812 342 6741 A Publication of the TURBO DIESEL REGISTER 12 VALVE NO START CONDITION The bolt that clamps the positive battery cable to the driver s side battery has a stud on its head with various leads attached One is the hot lead to the passenger side battery Two are fusible links one blue and one orange The blue one goes to the fuel shutdown relay Either this connector or the
111. and 59 For the definitive answer on coolant consulted the 1999 Owner s Manual Recommended Engine Coolant The manual reads Chrysler Corporation vehicles have been designed to operate on ethylene glycol based engine coolant Ethylene glycol based coolants are the only type recommended for use in your Chrysler Corporation vehicle Maintain cooling system solution at a 50 concentration of ethylene glycol antifreeze with water A higher concentration of antifreeze is recommended if temperatures below 37 F are anticipated but not to exceed 70 antifreeze A 50 antifreeze mixture should be maintained year round for protection against corrosion boiling or freezing If coolant is rusty or dirty discard and refill as recommended Do not use additional rust inhibitors or anti rust products as they may not be compatible with the radiator coolant The preceding passage from the 1999 Owner s Manual material does not give any specifics on the ethylene glycol based coolants to be used in your Turbo Diesel Is there newer information in later versions of the Owner s Manual A Publication of the TURBO DIESEL REGISTER Yes the 03 and 07 manuals are much more specific than the 99 book Reading from the manual Mopar antifreeze coolant 5year 100 000 mile formula HOAT hybrid organic additive technology 5011764AB or equivalent Wow is the HOAT coolant backward compatible with the good ole ethylene glyc
112. ansmission 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 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 Awasher is installed to prevent contact 89 AD with Speedometer drive gear replacement procedure manual transmission An information only brochure to supplement the service manual A Publication of the TURBO DIESEL REGISTER 31 CATEGORY 22 TSB 22 03 95 3 3 95 22 04 95 4 7195 22 05 95 A 6 30 95 22 06 95 6 16 95 22 03 94 6 24 94 22 05 93 7 16 93 22 02 92 4 6 92 MODELS 95 BR 94 95 BR 94 95 BR with code WDC wheels 95 BR 94 BR 93 AD 89 92 AD CATEGORY 23 BODY TSB 23 04 95 2 10 95 23 29 95 6 9 95 23 43 95 6 14 95 23 52 95 A 23 74 95 12 8 95 23 08 94 1 28 94 23 32 94 4 1194 32 MODELS 94 95 BR 94 95 BR 94 95 BR 94 95 BR Standard cab only 95 96 BR 94 BR 94 BR WHEELS amp TIRES SUBJECT DESCRIPTION Match mounted tire wheel combinations The bulletin is an information only bulletin describing a
113. ant to spend some time from above and below tie wrapping cables and wiring to make it easier to access the fuel filter From below the truck reach up and disconnect the water in fuel sensor wiring plug from the base of the fuel filter canister Again as Patton suggests you may want to de tang the sensor wiring plug connector l like the idea of extending the fuel filter drain hose Do so by slipping some 5 8 ID hose over the existing plastic hose or remove the plastic hose and permanently replace it with a longer length of 3 8 ID hose Loosen the drain valve on the bottom of the canister by twisting the 2 plastic star wheel counterclockwise and allow the canister to drain As mentioned you ll not be able to drain much fuel Now for the tip of the quarter Using a 1 2 ratchet and a 1 2 extension long enough to reach the bottom of the canister insert the 1 2 drive tip of the extension in the slot in the bottom center of the filter and back it out one turn You can now remove the canister by hand from above or below taking care not to spill the remaining fuel in the canister I ll bet you didn t know that there was a 1 2 drive indentation on the bottom of the filter canister The replacement canister contains a new filter element and the water in fuel sensor Simply apply the supplied replacement O ring to the male end of the canister and screw it in by hand Hand tighten it Reconnect the water in fuel se
114. aper clean the gear housing gasket surface and the gear housing cover 15 Remove the crankshaft oil seal from the gear cover using a punch or seal driver Located in the kit is a new crankshaft seal seal driver crankshaft seal starter and a dust shield Install the new crankshaft seal in the gear housing cover applying loctite to the outside of the seal Using the seal driver install the new seal in the gear housing cover making sure it is square in the opening Clean all oil residues from the gear housing cover and gear housing gasket surface and any old gasket material Apply a light coating of RTV or an oil resistant weather trim adhesive to the gasket surface area of the gear housing cover and place the new gasket on in the proper orientation Clean all oil off the front of the crankshaft The new Teflon seal must be installed on a clean dry surface Using the crankshaft seal starter in the new seal place the gear housing onto the front of the engine push the gear housing cover over the crankshaft nose and remove the seal starter from the crankshaft Start a couple of bolts to hold cover in place 16 Reinstall the gear cover bolts and torque to 18 ft Ibs 17 lt Reinstall the four 15mm engine dampener bolts and torque bolts to 92 ft Ibs 18 lt Reinstall the engine speed sensor Set the sensor to vibration damper air gap to 0 49 in minimum to 0 51 in maximum Make sure that the two notches in the d
115. arance between the cowl and instrument panel support joint 23 46 96 94 96 BR Rattle in door area 8 2 96 Inspect the area of the door latch face around the lower window channel retaining bolt If necessary perform the outlined repair procedure A Publication of the TURBO DIESEL REGISTER 39 CATEGORY 23 BODY Continued 23 69 96 97 BR Repair procedure for fallout damaged paint 11 22 96 Mopar Parts has released a new product Mopar Fallout Removal Kit p n 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 AIR CONDITIONING TSB MODELS SUBJECT DESCRIPTION 124 01 96A 94 96 BR Heater A C system changes mode to defrost when accelerating 10 18 96 This bulletin supersedes TSB 24 01 96 2 2 96 The vacuum supply line to the Heater A C system may drop when accelerating or when speed control engages This may cause the vacuum motor to switch to defrost The repair involves the addition of a vacuum check valve to the vacuum system 24 12 96 96 BR Water leaks from HVAC floor outlet onto floor 8 2 96 Vehicles assembled Water may drain out of the HVAC floor outlets while operating the A C sys
116. arch in last issue s Turbo Tips where he gave us a collection of low cost solutions to common problems we encounter 7 COOLING Installing a piece of metal screening in front of the truck s radiator is strongly recommended With three radiators engine cooling air to air intercooler air conditioning condenser it is important to have maximum airflow and minimum clogging due to bugs chaff and dirt The screen should also stop radiator penetration by rocks 9 ENGINE When changing the serpentine accessory drive belt always check the idler tensioner pulley to make sure its bearing is good The belt change interval is every 100 000 miles The turbocharger to intercooler to intake manifold piping clamps can come loose causing loss of turbo boost Check all rubber boots and clamps periodically for boot slippage under the clamps particularly if a loss of performance or a whistling noise is noticed while the engine is under load Periodically inspect the engine water pump bearing for leakage If any coolant is seen to drip or weep from the pump shaft area replace the pump before it fails 14 FUEL Trucks using an aftermarket remote mounted fuel filter have experienced abrasion of one or both hoses where they have contacted engine parts other underhood parts or each other Cover both lines with convoluted loom or rubber hose and route them in such a manner that they don t touch anything A few 97 trucks equipped w
117. are 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 00 BR 5 9L 24V Cummins diesel low power or poor performance diagnostic 11 15 99 The vehicle operator may complain of slow acceleration or a lack of power when towing or hauling moderate to heavy loads The condition may be worse at higher altitude This bulletin involves diagnostic procedures that may be used to assist the technician in the diagnosis of a low power or poor performance complaint The procedures outlined start with confirmation that TSB 18 11 98 turbocharger wastegate actuator repair kit has been performed Additionally the technician should verify that the throttle is opening fully e Perform the complete FUEL TRANSFER PUMP PRESSURE TEST procedure A Publication of the TURBO DIESEL REGISTER 53 CATEGORY 18 VEHICLE PERFORMANCE Continued e Inspect the fuel tank rollover valve for restrictions and to ensure that
118. at is diesel fuel rated and more heat resistant is the solution Low fuel system pressure that causes low power and stalling at hot idle especially in automatic transmission trucks may not necessarily signal a failing lift pump It can also be caused by a failing fuel overflow valve that bypasses too much fuel through the injection pump Low power and smoke complaints point to intercooler piping that may not be tight Additionally the fuel heater pre strainer is probably clogged This strainer is used only on the Dodge application The nylon pre strainer clogs with trash restricting fuel flow to the lift pump and injection pump Clean pre strainer by unscrewing the bottom of the unit or replace it if damaged Another 12 valve specific problem the quad ring on pre strainer bowl is cut or distorted Dodge offers a kit that consists of a new strainer and a new quad ring O ring with squared edges for the strainer bottom assembly for about 32 The strainer seldom fails Anew quad ring is available at most rubber supply and larger auto supply stores for a buck or two Ref These problems with the 12 valve low pressure fuel system were covered in detail in Issue 49 pages 148 152 THIRD GENERATION Glitch Third Generation performance and fuel issues The lift pump located in the area of the fuel filter is being upgraded replaced by Dodge dealers with the in tank fuel lift pump as used on the 05 trucks when failure on earlier mode
119. ate which is located on the left side of the engine affixed to the side of the timing gear housing Vehicles that are used for extended heavy trailer hauling purposes may experience a loss of exhaust manifold bolt torque This condition may lead to exhaust gas blow by past the exhaust manifold gasket s and even loss of exhaust manifold bolts Anew exhaust manifold bolt retention strap has been released as a means of locking the outboard exhaust manifold bolts in place This will prevent bolt rotation and torque loss during the thermal expansion and contraction cycles of the exhaust manifold A Publication of the TURBO DIESEL REGISTER 6 _ CATEGORY 9 ENGINE Continued 09 001 01 01 Intermittent loss of oil pressure sensor ouput voltage 1 19 01 This bulletin applies to 2500 3500 diesels with engine serial number 56744083 to 56809910 The output voltage of the oil pressure sensor may intermittently dropout This condition may cause the engine oil pressure gauge needle to erroneously indicate lower than actual oil pressure A warning chime may sound and the Check Gauges lamp may illuminate The Engine Control Module ECM software has been revised to address this condition Replacing the oil pressure sensor will not correct this condition 09 003 01 All Engine oil additives supplements 5 4 01 Engine oil additives supplements EOS should not be used to enhance engine oil performance Engine oil additives supplements should no
120. ate accelerations between 1500 and 2500 rpm May be accompanied by white smoke e During cold ambient temperatures 30 or below white smoke and or engine stumble when engine is started after an extended cold soak e During cold ambient temperatures 30 or below white smoke when restarting engine that has not yet reached normal operating temperature If the vehicle operator describes or the technician experiences the problem perform the repair procedure which involves erasing and reprogramming the Cummins ECM with new software 84 A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE Continued 18 033 04 8 20 04 18 041 05 12 20 05 18 001 06 Rev A 7 12 06 18 003 06 Rev A 09 27 06 18 005 06 Rev B 05 31 06 18 022 07 03 14 07 98 5 02 BR Cummins engine control module ECM procedure 03 05 DR Mopar is phasing out pre programmed Cummins diesel engine control modules ECM New modules will no longer be pre programmed when received from Mopar Replacement of future ECM s will require programming at the dealership This bulletin describes the programming procedure 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 desi
121. ated on an extreme downhill grade 36 5 or 22 slope grade Operation of this type for extended periods of time can cause enough engine oil depletion to damage the engine A kit containing all components necessary to eliminate the oil overflow has been made available The bulletin outlines the repair procedure that relocates the breather from the front of the engine to a new location on the driver s side tappet cover CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS SUBJECT DESCRIPTION 18 31 1 98 5 2002 BR BE Cold idle engine warming New This bulletin involves selectively erasing and reprogramming the Engine Control Module with new Release software This bulletin applies to all Ram trucks built after December 17 1997 equipped with the 24 valve 5 9L Cummins diesel engine Extended idle operation especially in cold weather can allow varnishes oils to condense on the exhaust valve stems leading to stuck valves and damaged valve train components The repair procedure involves calibration software that will activate when certain parameters are met reducing the chance of valve sticking as well as improving cab heat warm up time Idle speed will slowly ramp up from 800 rpm to 1200 rpm when all of the following conditions are met Intake Manifold Temperature less than 60 C 32 F Coolant Temp is less than 60 C 140 F The transmission is in Neutral or Park The Service Brake pedal is not depressed Throttle 0 Vehicle Speed 0 m
122. available Engine Ratings Same as 98 599 model years 235HP 460 ft lbs torque for manual transmissions 215 HP 420 ft lbs torque for automatic transmissions Transmissions Five speed manual NV4500HD 5th overdrive Six speed manual NV5600 6th overdrive Four speed automatic 47RE 4th overdrive with locking converter The six speed manual transmission has the same first and overdrive ratios as the five speed with an additional ratio interposed between second and fourth gears Fifth gear is direct A Publication of the TURBO DIESEL REGISTER Maximum Tow Ratings 2500 regular cab and quad cab 4x2 both manual transmissions both axle ratios 20 000 GCWR 2500 regular cab and quad cab 4x4 both manual transmissions both axle ratios 20 000 GCWR with the exception of the quad cab 4x4 short bed 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR 2500 regular cab and quad cab 4x2 and 4x4 automatic 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR 3500 regular cab and quad cab 4x2 and 4x4 long bed both manual transmissions both axle ratios 20 000 GCWR All 3500 automatics 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR Cab Chassis Models Available in regular cab only 2500 is 8 800 GVWR 56 C A cab to axle dimension 3500 is 11 000 GVWR and available in 60 and 84 C A dimensions GCWR is same as tow ratings above Comments The 2000 model year Dodge truck was a production run of only three months Effective o
123. ay prompt many of you to reread an article or two No doubt that you have more experience since you first read the article and to read it again now will give it new meaning A Publication of the TURBO DIESEL REGISTER Best Tips What is the best tip you ve received from the magazine or website saved the most money time or aggravation As editor it is tempting to cite the following answer given by a respondent The whole concept of self help and preventive maintenance that is presented in the magazine and on the website is irreplaceable get my 35 worth every year all of the magazines are good So there is your answer all of the magazines are good and the website is irreplaceable However can t get away without presenting specifics So in no particular order here is a brief list of the best tips that were submitted The seat fix for the sinking feeling Issue 35 page 14 12 valve throttle cable break a few weeks later mine broke and was prepared for the problem Issue 34 page 44 12 valve return fuel line crack problem Issue 24 page 19 NV4500 fifth gear nut problem Issue 24 page 26 24 valve pusher pump installation Issue 34 page 47 Fog light relay jumper keeps fog lights on with high beams Issue 23 page 23 Cary a spare fuel filter no particular issue just good common sense Changing engine coolant Issue 35 page 76 Oil filter disposal in a bag Issue 26 page 18 Exhau
124. b models are rated for lower maximum trailer weights than standard cab models Highest trailer weight rating is for a 2500 regular cab 4x2 manual transmission long bed 14 150 pounds trailer Lowest trailer weight rating is for a 3500 quad cab 4x4 automatic transmission 3 54 axle 9 050 pounds trailer Cab Chassis Models Available in regular cab only 2500 is 8 800 GVWR 56 C A dimension 3500 is 11 000 GVWR and available in 60 and 84 C A dimensions Tow ratings are same as above Comments Six speed transmission removed from sale due to quality control issues Users find the 4 10 axle ratio is best for towing with the 24 valve engine 2000 Turbo Diesel What is New Optional fold away towing mirrors Optional automatic dimming rear view mirror Revised front disc brakes with two piston calipers 4 wheel anti lock brakes standard on 3500 series trucks Added radio with CD changer controls Changer is a dealer installed Mopar accessory Deleted body side moldings from entire bed sides Deleted extended cab option leaving only the quad cab option Anti spin rear axle only available in 4 10 ratio Optional 265 75R 16E Michelins on 7 5 x 16 cast aluminum wheels for all 2500 models 3500 series standard tires are now LT235 85R 16E using steel wheels of greater offset Models Available 2500HD as standard cab quad cab short bed long bed cab chassis 4x2 and 4x4 3500 Same as above No short bed models
125. beads on the waxed surface Clean window glass with a mixture of ammonia and warm water applied with a cloth or sponge Dry the glass with old newspaper pages Cheap and effective To clean your engine use a solution of Simple Green in water Spray it on a cold engine let it sit briefly hose it off Contributed by Don Mallinson and Robert Patton Installing a pyrometer gauge in the exhaust provides the greatest accuracy in assessing exhaust temperature Pyrometer temperature should read less than 300 degrees before shutting down when measured in the elbow after the turbocharger Gauges are available from Geno s Garage Call 1 800 755 1715 Extended idling over 10 minutes is not recommended by Cummins On 99 and newer trucks with central locking the doors automatically lock at speeds above 15 MPH Your owner s manual explains how to disable this feature if you desire A Publication of the TURBO DIESEL REGISTER PREVENTIVE MAINTENANCE FOR DODGE TRUCKS All vehicles develop maintenance problems that require special attention to prevent breakdowns or part failures The following is a list of special areas on Turbo Diesel trucks that warrant attention These items have been discovered through miles and miles of driving by the TDR membership This list is categorized in the same classification as Dodge s Technical Service Bulletins The list was compiled by TDR correspondent Jim Anderson This is an excellent complement to Jim s rese
126. blems A Borgeson steering shaft helps on almost any truck and First Generation four wheel drives often benefit from an adjustable drag link a mild drop pitman arm or on really heavy front ends an upgrade or replacement of the upper kingpin bushing a much simpler job than it sounds Two wheel drive versions benefit from a set of Moog ball joints Later model 4WDs tend to wear out trackbars and Luke s Link appears to have the fix for that one In some First Generation trucks the steering box broke off the frame rail or the box moved on the frame from elongated bolt holes Like many 70s vintage GM 4x4s adding a brace from the opposite side frame rail fixed it but unlike the GMs the aftermarket did not develop a kit for it Worn axle U joints 4x4 only along with other worn front end parts could cause a phenomenon known among Dodge diesel owners as a death wobble that was set up by crossing a seam in the road that ran at an angle to the direction of travel Cure inspect replace any loose or worn front end component including wheel bearings front axle U joints hubs tie rod ends pitman arms steering boxes ball joints steering stabilizer track bar etc The cumulative slop of all the above components leads to the death wobble Ref 33 p 41 I 35 p 13 146 p 20 100 Glitch My truck s dripping oil Fix Not until many years into the Dodge Cummins partnership did the engine have PCV it was positively
127. cedure which includes a steering damper tie rods and end links 22 002 07 08 DH Tire pressure monitor system TPMS Light Load reset switch and tire rotation caution Rev A 2500 This information only bulletin provides information for new vehicle preparation setting tire 7 12 07 pressures rotating tires and the right load switch on vehicles with the tire pressure monitoring system installed CATEGORY 23 BODY TSB MODELS SUBJECT DESCRIPTION 23 018 03 03 DR Instrument panel whistle 6 13 03 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 03 DR Buzzing or vibrating sound coming from the front of the vehicle 6 13 03 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
128. celeration This condition may occur when transmission sump temperatures are 32 degrees F OC or higher Changes to the Cummins CM551 engine control module ECM software calibration corrects the above two conditions calibration change 00Cal57T9A 21 19 99 99 00 BR 47RE delayed TCC lock up and or MIL P1740 TCC or O D solenoid performance 11 12 99 This information applies to vehicles built for the California market NAE equipped with a 5 9L 24V diesel engine and built between March 2 1999 and October 1 1999 The customer may experience a delayed torque converter clutch engagement lock up This condition may illuminate the Malfunction Indicator Lamp MIL due to Diagnostic Trouble Code DTC P1740 TCC or O D Solenoid Performance In some situations the customer may describe the condition as a lack of a transmission shift TCC lock up between 30 and 50 mph The transmission valve body upper housing separator plate was revised wider slot to improve fluid flow to the torque converter clutch This bulletin describes the replacement of the transmission valve body upper housing separator plate CATEGORY 23 BODY TSB MODELS SUBJECT DESCRIPTION 23 08 99 94 99 BR Instrument panel creak 03 05 99 This bulletin supersedes technical service bulletin 23 45 96 dated August 2 1996 A creak or squeak may be present near the left and or right side s of the instrument panel The noise is caused by the sheet metal joint betwee
129. cks equipped with the 24 valve Cummins diesel engine may experience engine oil overflow from the front crankcase breather when the vehicle is operated on an extreme downhill grade 36 5 or 22 slope grade Operation of this type for extended periods of time can cause enough engine oil depletion to damage the engine A kit containing all components necessary to eliminate the oil overflow has been made available The bulletin outlines the repair procedure that relocates the breather from the front of the engine to a new location on the driver s side tappet cover A Publication of the TURBO DIESEL REGISTER 65 CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS SUBJECT DESCRIPTION 18 019 01 98 5 02 BR BE Cold idle engine warming 9 3 01 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 Tempe
130. ckup models 2500 and 3500 the automatic and manual transmission are the same as those used in the 07 5 and 08 The nomenclature for the automatic transmission is the 68RFE the nomenclature for the manual transmission is G56R The gear ratio comparison chart is found in the 2007 Turbo Diesel write up Commercial Chasis Cab models 3500 4500 5500 use the same G56R manual transmission and Aisin AS68RC six speed automatic transmission Maximum Towing Capacities No changes from the listing chart for 2008 Publishing the past and present ratings for your Turbo Diesel is as easy as making a chart The horsepower and torque numbers make good copy but you ll note from the chart on the next page that there are two additional columns CPL and Comments The comments column is self explanatory CPL is a Cummins abbreviation that stands for control parts list The CPL provides a comprehensive breakdown of performance hardware i e pistons turbo camshaft injectors and fuel pump that were used in the engine build The CPL number along with the Cummins engine serial number will help your Cummins parts professional should you need engine hardware A Publication of the TURBO DIESEL REGISTER Your Notes A Publication of the TURBO DIESEL REGISTER 15 16 Your Truck and the Boost Treadmill Boost specifications The TDR magazine has often been criticized for being too technical should take an opportunity to e
131. cles 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 above vehicles may allow water to enter into the fuel tank Excessive water in the fuel can damage the injection pump and or injectors if the engine is off for an extended period of time Repair A vent hose must be installed at each tank roll over valve ROV The fuel system must be inspected for excessive water content If excessive water is found the water must be removed and the fuel filter must be replaced EMISSIONS RECALL G30 REPLACE OXYGEN SENSOR MODULE AND REPROGRAM ECM Date October 2007 Models 07 08 DH D1 Dodge Ram 2500 3500 Pickup Truck This notification applies only to the above vehicles equipped with a 6 7 liter diesel engine built 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
132. cles 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 MMMM MM 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 c
133. d A brake system evaluation is outlined Steering and suspension inspection is discussed Suspension torque values for fasteners are discussed A suspension geometry evaluation is outlined Front end alignment specifications are provided Wheel shim kits and installation of shims for 4x4 trucks is discussed CATEGORY 8 ELECTRICAL TSB MODELS SUBJECT DESCRIPTION 08 20 96 96 97 BR Cassette auto load error on RAS code radio 7 19 96 This information only bulletin describes a condition where the radio may enter the cassette play mode without a cassette being inserted The bulletin explains the correction and discusses the function of the Ignition Off Draw IOD fuse 08 21 96A 96 BR Wiring harness connector repair packages 10 18 96 This information only bulletin helps the service 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 94 96 BR Clicking noise from speedometer 8 23 96 built prior to 12 15 96 If a clicking ticking noise is heard coming from the instrument cluster area the bulletin describes the repair procedure to replace the speedometer 08 33 96 94 97 BR Trailer tow wiring information 10 11 96 Chrysler Corporation has offered optional trailer tow packages on all 94 through 97 Dodge Ram Trucks and has made trailer tow packages available through Mopar for vehicles tha
134. d with clear nail polish to keep it from coming loose Ifa vehicle battery is constantly boiling over check and clean the ground from the alternator and or voltage regulator to the vehicle frame A poor ground connection will cause the alternator to put out too much juice Measuring alternator output with a voltmeter may show it is putting out 14 8 volts or more when it should charge at 14 2 volts When the rubber boot covering your positive battery terminal connector becomes worn replace it with an old spark plug wire boot or make a sleeve type cover from an appropriate size plastic bottle Just a reminder when replacing quartz halogen lights use clean cloth gloves or otherwise cover the bulb with clean cloth or paper to prevent oil from your hands getting on the glass Finger oils make the glass shatter under high heat conditions LUBE TIPS Trying to pour oil or other fluid into a fill hole and don t have a funnel handy Stick a screwdriver in the fill hole and pour the liquid down the screwdriver shaft It will follow the shaft into the fill hole Need some good parts cleaning solution but hate to spend the bucks Use old automatic transmission fluid It will make greasy parts shiny clean after an overnight soaking Wash the ATF off with soapy water If you have a mysterious oil leak on your automatic transmission check where the transmission dipstick tube goes into the case You ll likely find a cracked O ring when
135. d 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 A Publication of the TURBO DIESEL REGISTER PCN with new software 59 CATEGORY 21 TRANSMISSION Continued 21 08 00 99 00 BR 47RE delayed TCC lock up and or MIL P1740 TCC or O D Solenoid Performance 09 01 00 This information applies to vehicles build for the California market NAE equipped with a 5 9L 24V diesel engine and built between March 2 1999 and October 1 1999 The customer may experience a delayed torque converter clutch engagement lock up This condition may illuminate the Malfunction Indicator Lamp MIL due to Diagnostic Trouble Code DTC P 1740 TCC or O D Solenoid Performance In some situations the customer may describe the condition as a lack of a transmission shift TCC lock up between 30 to 50 MPH The transmission valve body upper housing separator plate was revised with a wider 0 470 inches slot in the lockup vent circuit to improve fluid flow in the torque converter clutch This bulletin invo
136. d into the remaining fuel rather than spraying on the tank s upper surface introducing foam and air Supply and return Ule bucket note the slide has bee Sticking rather than smoothly Screw ts sometimes the cause leaking A Publication of the TURBO DIESEL REGISTER Permit me to further digress recently made a road call to visit a sick 95 model truck The owner complained of a tapping noise and suspected connecting rod since the truck showed about 250 000 on the odometer Over the phone when he held it near the source of the noise it sounded to me like a worn out lift pump tapping away on the cam lobe The problem was missing fuel line routing brackets which mount to the bell housing It seems that the clutch had been recently changed and assume the technician was speeding along attempting to beat the book flat rate and didn t see the need to attach the awkward brackets The supply and return were chattering away on the bell housing which was driving its owner to near insanity Some zip ties and split pieces of fuel line temporarily solved the problem while the replacement brackets were ordered Again due to age the fuel heater pre filter is a common repair area on 12 valve Turbo Diesels TDR member Joe George showed us his method for finding a problematic air leaks at his fuel heater several issues ago compressed air and a bucket of water Joe s dilemma was much like Brandon s Quoting from Issue 44
137. d maintain the low gloss appearance should be used for interior trim treatment 23 049 05 04 05 DR Drip rail door seal torn 10 12 05 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 04 05 Water leak at roof mounted marker lamps 2 14 06 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 92 A Publication of the TURBO DIESEL REGISTER CATEGORY 23 BODY Continued 23 014 06 All Chrysler Group Windshield wiper blade maintenance 3 8 06 Vehicles Windshield wiper blades elements are frequently replaced unnecessarily If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades elements is obvious the following steps should be performed e Use a soft cloth or sponge and squeegee and a solution of 50 50 alcohol and water to wash the windshield e Raise the wiper blades off the glass and clean the wiper blade elements with a solution of 50 50 alcohol and water and a soft clot
138. diator or simply cover the radiator with window screen material Then a few taps of the hand will remove the collected bugs This quick fix provides a free or almost free preventive maintenance solution For extreme cold weather operation if you install a winter front radiator cover on your truck it must have a minimum one square foot opening in its center for radiator and intercooler airflow This tip is from the Cummins 5 9 Liter Engine Operation s Manual The correct type of antifreeze coolant to use in your Turbo Diesel is an ethylene glycol not propylene based product If possible use a low silicate diesel type of coolant It should be mixed fifty fifty with distilled water Or you can buy a pre mixed product But if you mix your cooling system 8 ELECTRICAL On 89 93 trucks the voltage regulator seemed to fail too often Member Earl Peck solved the problem by relocating the regulator to the front of the hood pivot assembly on the left side of the engine away from all the engine s heat His regulator hasn t failed since On second generation trucks Dodge redesigned the system and the regulator is integral with the alternator and it is not a problem On some maintenance free batteries it is possible to check the electrolyte level If the case is transparent or white plastic shine a flashlight on the case while looking at the other side of the case The liquid level will clearly show Try this in a garage or ot
139. ding for calendar years are anticipated 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 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 A Publication of the TURBO DIESEL REGISTER 4 CATEGORY 9 ENGINE TSB MODELS SUBJECT DESCRIPTION 09 06 98 98 BR Incorrect engine oil dipstick 10 30 98 This information applies to vehicles equipped with 24 valve Cummins diesel engines Some early 1998 24 valve diesel engines were built with an incorrect dipstick calibration This incorrect marking causes an overfilled condition of approximately 1 1 2 quarts when at the top end of the safe zone on the dipstick This overf
140. due to one of the following DTC s P0106 Manifold Absolute Pressure Sensor Performance P242B Exhaust Gas Temperature Sensor Circuit Performance Bank 1 Sensor 3 P245A EGR Cooler Bypass Control Circuit Open e An intermittent rough engine idle and or white smoke following initial engine start Athrottle 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 e A turbocharger chuff like sound during rapid deceleration This bulletin involves selectively erasing and reprogramming the Powertrain Control Module PCM with bootloader software and application software A Publication of the TURBO DIESEL REGISTER 87 CATEGORY 18 VEHICLE PERFORMANCE Continued 18 037 07 07 DH D1 This bulletin applies to vehicles equipped with a 68RFE automatic transmission sale code DG7 Rev A built on or before April 30 2007 The customer may experience a malfunction indicator lamp 07 20 07 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 07 08 Engine system and exhaust aftertreatmen
141. dure involves a change in the front axle lubricant or possibly a parts component replacement 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 89 93 AD with Four speed automatic transmission 4 3 downshift clunk automatic The bulletin describes a clunk or harshness during 4 3 coast downshift at approximately 18 20 transmission mph Verify all engine and transmission systems are functioning properly Repair as required 92 93 AD with Delayed up shifts and harsh engagement into drive or reverse automatic The bulletin describes a repair involving adjustment of the throttle valve cable and replacement transmission of the return spring 89 91 AD with 3 4 up shift noise with A 518 transmission A 518 automatic A noise or rattle during 3 4 up shift or down shift may be the result of an overdrive clutch pack transmission vibration Diagnose the vehicle to confirm condition and repair as necessary 89 90 AD with Replacement of transmission shift lever and stubshifter manual tr
142. e 2500 or 3500 single rear wheels or 3500 dual rear whels It is only offered with a short cargo box Chassis Cab Models The 3500 is available in single or dual rear wheels The 4500 and 5500 are dual rear wheels All three Chassis Cabs are available with a regular cab or Quad Cab configuration A Publication of the TURBO DIESEL REGISTER With the 3500 the regular cab can be purchased with a 60 inch cab to rear axle length or a 84 inch cab to axle length with single or dual rear whels SRW DRW The 3500 Quad Cab can only be purchased with the 60 inch cab to rear axle lenth with SRW or DRW The 4500 and 5500 trucks are only offered with dual rear wheels These trucks allow regular cab or Quad Cab cabins to be used with the 60 inch or 84 inch cab to axle length Engine Ratings Same as 2007 For 2008 the engine ratings for the Cummins 6 7 liter engine in consumer pickup models 2500 and 3500 remained the same as they were when the engine was introduced in January of 2007 350 HP and 650 ft lbs of torque with the automatic transmission and 350 HP and 610 ft lbs of torque with the manual transmission The engine ratings for the Cummins 6 7 liter engine in the Chassis Cab models 3500 4500 and 5500 remained the same as they were when the engine was introduced in the first Chassis Cab 3500 model in March of 2006 305 HP and 610 ft lbs or torque Transmissions In the consumer pickup models 2500 and 3500 the automatic and manual t
143. e 38 page 136 Issue 33 page 46 Additionally there is a thread on the TDR web site that takes you through the how to should one wish to use the drill jig method However on a recent visit to TST s shop outside Columbus Indiana discovered yet another way to perform this preventive maintenance type procedure A Publication of the TURBO DIESEL REGISTER For those not familiar with the dowel pin the arrow shows its location Above is a picture of an egg shaped washer that is their solution to the problem Again many methods of dowel pin preventive maintenance have been previously discussed Using some TST shop short cuts and the TST developed egg washer the task of dowel pin correction has been reduced from highly involved A Publication of the TURBO DIESEL REGISTER to a job that can be tackled by the shadetree mechanic A brief descriptive of the steps involved again shadetree type work as itis simply parts removal and installation and a few key pictures will take you through the major steps TST has a comprehensive set of instructions an egg washer with a longer gear cover bolt a Cummins crankcase seal a tube of gasket maker RTV for the front cover The price for the kit is 48 As a note TST suggests that you consider a replacement fan belt it s time to change the belt and keep the old one for a spare and replacement hoses time to change these too You ll find other vendors offer these replaceme
144. e Mopar manual transmission fluid Mopar part number 4874464 or Texaco 1874 These are the only lubricants recommended for use in the NV 5600 transmission This is another example of a lubricant that you will not find at the local auto parts store We ve yet to do a full blown expos on the NV5600 s lubricant Discussions with Mike Patton owner of Standard Transmission and Gear revealed the following The New Venture 5600 gearbox uses a synthetic 30 weight oil From New Venture literature we know to use the Mopar 4874464 part number However Pennzoil Synchromesh 30 weight synthetic fluid has been confirmed as an acceptable alternative The Pennzoil will likely not be easily found but they ve got it in stock at Standard Transmission 2005 Current Six Speed G56 Manual Transmission The lube oil recommended for the G56 transmission is Mopar ATF 4 Mopar ATF 4 is readily available at your local auto parts or Mopar dealership AUTOMATIC TRANSMISSION FLUID For the automatic transmission the latest DaimlerChrysler specification calls for the use of ATF 4 type 7176 Unlike the scenario of GL 4 versus GL 5 in which the former is good but the latter is not better the latest ATF 4 type 7176 can safely be used in all previous 47 RE RH automatic transmissions In this case logic prevails if 3 is good then 4 is better This information was verified by D C s customer advocate personnel If you have any doubts about
145. e TDR as well as those interested in the purchase of a truck With the ever changing ownership of vehicles the idea of a Turbo Diesel Buyer s Guide makes perfect sense To that end the editor asked me to do a study of changes by model year to Dodge Cummins trucks Since its1994 introduction the current body style Dodge Ram pickup has undergone many changes and modifications To properly compile such a list changes for each model year seem to build on each preceding model year and therefore you may want to read from the start 1994 to see total changes and cumulative modifications for the particular model year you wish to research Each model year after 1994 contains changes in the form of additions and deletions to the previous model s Only major changes and major new options are covered As you know each year contains changes to paint colors and schemes and interior upholstery colors and materials These are not outlined in our research Likewise many minor technical adjustments and changes such as a change in tailgate hinge pin diameter are not listed as they don t really affect the overall performance of a given model Changes and modifications covered will only be for those truck models 2500 and 3500 pickup and cab chassis models which were offered with the Cummins Turbo Diesel engine option package Sharp eyed owners may pick up discrepancies and or errors of omission These errors are solely the responsibility of yo
146. e advised that the cooling system is large to provide capacity and protection for high temperatures and high GCWR ratings Slower warm ups are to be expected 07 01 91 89 90 AD Overheating or no heat condition 1 28 91 An interference between the thermostat and 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 90 91 AD Lower radiator hose leakage 9 23 91 Some leakage from the lower radiator hose at the waterpump connection may occur due to a step cast in the water pump nipple The repair involves installing a second hose clamp 07 05 91 91 AD Fan belt noise chirp 12 16 91 The noise is caused by excessive paint in the grooves of the water pump allowing the belt to slip Wire brush and solvent to remove the paint is the repair procedure 07 03 90 All Recycled engine coolant 12 21 90 The use of reconstituted antifreeze coolants is not authorized in the performance of any repair covered under the provisions of warranty 07 01 89 88 89 with Auxiliary oil cooler freeze up 2 27 89 automatic transmission At ambient temperatures of 10 F or lower trucks with auxiliary coolers NHB may loose transmission fluid due to a restriction of oil flow A bypass line is the recommended repair CATEGORY 8 ELECTRICAL TSB MODELS SUBJE
147. e 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 transmission equipped vehicle This bulletin involves selectively erasing and reprogramming the MIC with new software 08 007 03 03 DR Alternator mounting bracket cracked 4 4 03 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 03 DR Lamp out indicator with aftermarket pickup box installation 6 20 03 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 A
148. e clutch pedal is pushed which binds the clutch as it slides on the input shaft splines Pilot bearing replacement is necessary along with replacement of the transmission input shaft if the nose of the shaft is not perfectly round or is scored While the Dodge input shaft is priced at over 500 the shaft can be bought in the same box with similar part numbers from other sources for about 100 Damage to both components can be avoided by using the clutch only for gear changes and not sitting with your foot on it Ref 150 p 36 149 p 10 136 p 75 A Publication of the TURBO DIESEL REGISTER Glitch Driveline vibration based on road speed Fix It sounds like a worn out driveshaft universal joint or unbalanced shaft but may also be caused by a bad carrier bearing or bearing support in a two piece driveshaft system The bearing cannot be re lubricated by the owner and the entire sealed carrier bearing assembly must be replaced This is presently a Dodge only part A heavy load in the lower gears will cause driveline windup as well leading to vibration that lessens with road speed or less torque applied to the axle On Third Generation trucks the driveline alignment should be checked as well FIRST GENERATION Glitch The front driveshaft on First Generation trucks falls out Fix With the newfound massive torque slipping front wheels that quickly found traction inevitably made the engine jump out of its mounts or snapped the little
149. e design specifications on the Carter lift pump are very close to if not exceeding manufacturer specifications guess now we know what happens when a part is pushed to its design limits e The kit lists for approximately 400 It likely requires about 4 5 hours of shop rate labor to install the kit DIY s should likely add more time e Reliability is unknown but Dodge must believe the design on the 05 up Turbo Diesels to be superior to the previous design A possible negative would be if a failure of the new transfer pump now located in the tank is experienced the additional labor required to drain drop the fuel tank and service the module pump assembly could be more expensive have personal experience with one retrofit so far My friend that works in Mopar wholesale parts has a 00 model which we diagnosed with an inoperable transfer pump One of his friends at the dealership a technician did the retrofit in a couple of hours Another feature is greatly reduced pump operation noise before the engine is started Unfortunately was unable to take photos while it was on the hoist at the dealership to show harness wiring routing etc Although I m a proponent of the popular FASS fuel system this would be a runner up As long as it proves reliable tip my hat to Mopar Andy Redmond TDR Writer Now my opinion NO Do not retrofit your truck In the prededing pages we ve covered the replacement of this troub
150. e discussion on the components from the fuel tank float and sending unit to the fuel transfer pump apply to all Second Generation trucks The term low pressure fuel delivery system covers the components from the fuel tank up to the truck s fuel injection pump and from the injection pump back to the fuel tank Common problems that will be discussed fuel level sending unit fuel heating element fuel transfer pump overflow valve fuel return line Let s start at the beginning the fuel tank The fuel tank is approximately 34 gallons and made of an injection molded type plastic material The tank utilizes a fuel tank module with an integral fuel level sending unit Carter Federal Mogul company is typically the fuel tank module manufacturer Walbro manufactures the sender The module is installed vertically in the fuel tank and is retained by a large plastic nut and o ring gasket to the threaded top of the fuel tank The module has a lower half that can float up and down somewhat on a slide system The purpose of the float is to prevent erratic fuel gauge readings due to fuel slosh when driving off road It also serves as a small basket which will hold approximately one quart of fuel This prevents air entrainment in the fuel system when the tank level is low and steep approach angles are tackled The top of the module has ports for fuel supply 3 8 and fuel return 5 16 a rollover valve tank vent an auxiliary fuel port and an el
151. e door hinge area If the door hinge bushing has fallen out the bushing should be reinstalled and crimped to prevent reccurance Creaking noise or exterior noise from back of cab The condition is a sheet metal creaking or exterior noise from the back of the cab caused by verticle or horizontal cracks in cab back Using a hoist and a strong light look for cracks on lower portion of cab If cracks are noted four cab reinforcements and replacement cab isolators should be installed Interior film build up on windows Window film build up is caused by vinyl interior trim material releasing gasses that adhere to the glass The condition lessens as the vehicle gets older Wind noise at front of door Inspect the vehicle for the appropriate seal If not present perform the repair installation procedure Door fit at roof line The top of the door should project higher than the roof panel Do not attempt a repair if the door falls within the overflush 1 3 mm condition A Publication of the TURBO DIESEL REGISTER CATEGORY 23 BODY Continued 23 36 94 4 22 94 23 39 94 5 6 94 23 40 94 A 5 6 94 23 41 94 5 13 94 23 45 94 6 3 94 23 49 94 7 1194 23 51 94 7 1194 23 60 94 8 12 94 23 63 94 8 26 94 23 68 94 9 30 94 23 71 94 10 7 94 23 73 94 10 7 94 23 95 94 A 12 30 94 23 98 94 12 23 94 94 BR Front door to windshield moulding squeak creak A noise from the front of door plastic windshield moulding can
152. e 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 98 02 BR BE Engine knock or rattle sound when climbing a long grade and towing a heavy trailer 10 21 02 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 CATEGORY 13 FRAME BUMPER TSB MODELS SUBJECT DESCRIPTION 13 001 03 03 DR Frame alterations 2 7 03 This bulletin is to support the 2003 Body Builder s Guide and presents guidelines that must be followed during modifications or alterations to any 2003 Dodge Ram pickup frame The following general industry standard procedures are recommended for proper installation of special bodies and or equipme
153. e increasing number of warranty claims When the article was written the early 98 5 engines were 2 5 years old The problems were aggravated by those that hot rod their trucks as well as purchase fuel system accessories that add restriction to the system The bottom line is that the 24 valve s Bosch VP44 electronic fuel delivery pump needs to see at least 5 6psi of pressure from the fuel transfer pump Less than 5 6psi more is better and there is a danger of overheating the VP44 pump for it uses fuel to cool and lubricate its internal parts In the photo note that the Editor s truck a 99 model is outfitted with two gauges one is a mechanical liquid filled gauge and the other is a Westach electrical gauge with a pressure sending unit mounted to the filter head assembly In order to install a gauge the 98 and 99 24 valve engines have a filter head with easily accessible 1 8 NPT fittings On the 2000 and up trucks the service design team at Cummins was mindful of the need to test the fuel transfer pump s delivery pressure Thus your truck is equipped with a banjo adapter with a Schrader valve assembly Say what For clarification let s look at a photo and a description On the inside the part with the rifled opening attaches the fuel line to the fuel pump On the outside the Schrader valve think A C valve or better yet a tire valve has a press for pressure needle Here is the catch you can take the
154. e lift pump mostly on P7100 trucks degrade over time and develop leaks And the clamps used tend to distort and often lead to their own leaks better to get some screw type band clamps when you do the job Ref 24 p 19 1 46 p 26 Glitch Engine quits tach drops to 0 Fix When your diesel behaves like a gas engine with broken points it s often a bad crankshaft position or camshaft position sensor Depending on the year it may also be characterized by the alternator cruise control air conditioner compressor not working properly failure of the automatic transmission to engage overdrive or failure of the lockup clutch to operate The crankshaft position sensor is located on the front of the engine immediately above the crankshaft pulley on 12 valve engines or behind the starter on 24 valve engines Without a cam or crankshaft position signal going to the PCM the above features won t operate Replacement of the sensor restores operation This is a Cummins part not a Dodge part Glitch Shut down solenoid is shut down Fix The fuel shutdown solenoid on 94 98 12 valve trucks has caused its fair share of difficulties leaving trucks that won t start won t stay running or won t shut off In some cases a manual approach to fixing it much like tapping an old starter solenoid with a mallet might get you home An alternate method is to delete the start run solenoid and replace it with a cab controlled cable to mo
155. e possibility of an unhappy customer was too ominous Robert Patton TDR Staff A Publication of the TURBO DIESEL REGISTER 24 VALVE 98 5 02 OWNERS WHAT TO DO The First Step Buy a Gauge If you are the owner of a 98 5 02 Dodge Cummins Turbo Diesel truck it is mandatory that you purchase a fuel pressure gauge A gauge allows you to monitor the fuel transfer pump s performance and correct a small problem before it becomes a big and expensive problem the replacement of the VP44 fuel injection pump Mandatory Buy a gauge That is right a gauge Do not trust the low fuel pressure idiot lights Your gauge will allow you to watch fuel pressure trends A light tells you it is too late So which fuel pressure gauge should you choose From listening to the guys at Geno s Garage they recommend the Westach fuel pressure gauge It is an electrical gauge It is inexpensive and easy to install The price is about 75 for a Westach gauge 200 for Autometer Owners of the 00 02 trucks will need a 19 fuel pressure line to allow you to marry a fuel pressure sending unit to the fuel system Alternately you can purchase a mechanical fuel pressure gauge This design will have a pressure isolator that is mounted under the hood The isolator is an interface that keeps diesel fuel in the engine compartment a glycol fluid fills the capillary tube that goes through the firewall into the cab and to the back of the gauge Mechan
156. e should contain less moisture and sediment Engine Oil Use any high quality lube oil diesel rated 15W 40 with the API donut symbol CH 4 SH or better such as Cummins Premium Blue Shell Rotella T Chevron Delo 400 For very cold weather operation you may use a diesel rated 10W 30 meeting the same API spec as above Do not use synthetic oil if your engine has less than 10 000 miles on it Engine Fuel Filter Fill the fuel filter with fuel before installation and purge all air from the fuel system before starting the engine Issue 25 page 84 has the details on a 24 valve fuel filter change Change Intervals Change your engine oil and oil filter according to the chart in your Owner s Manual Change the fuel filter at every other oil change Neither Dodge nor Cummins recommends using extended drain intervals with the use of synthetic engine oils Change transmission and axle fluids according to the types of service listed in your Owner s Manual Anti freeze Coolant Drain and refill every 24 to 36 months using low silicate diesel rated ethylene glycol based coolant Pre mix half and half with distilled water before installation or addition Automatic Transmission fluid Change fluid and filter every 40 000 miles for normal operation For operation such as towing or heavy loads change every 15 20 thousand miles The latest Mopar specification is ATF 4 type 7176 The latest ATF 4 can safely be used in all previous 4
157. e 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 07 DH D1 Ram truck 2500 and 3500 Excessive soot accumulation in exhaust PCM may not reprogram Rev B OBD readiness status and other engine system enhancements 06 28 07 This bulletin applies to Ram truck 2500 and 3
158. e wrenches of a certain type to make them easier to identify A Publication of the TURBO DIESEL REGISTER If your ratcheting socket wrench handle constantly bangs on nearby metal while in use slip a piece of rubber tubing over the handle end to cushion it If you want to magnetize a screwdriver or other tool stroke its tip with a magnet If you want to demagnetize a tool run the shaft or tip between the electrode arms of a soldering gun while it is turned on Slip a tube of closed cell foam pipe insulation over your floor jack handle to keep it from damaging the paint on the body sides of your ride Leave the top of the handle clear for a good grip Make an old dental pick a part of your toolbox It has many uses such as picking up small parts scraping gasket material out of tight corners cleaning grease out of cracks and aiding in assembly of small parts Cleaning up your tools after a project is fast and easy with this tip Spray them with carb cleaner and then wipe them dry and clean before putting them away THRU THE LOOKING GLASS If your wiper blades streak the windshield or otherwise act as if they are worn out don t replace them Just sand them That s right run a block with wet 600 grit paper along the rubber wiper edge for a few strokes to remove the small cut places in the blades and they ll work like new If your windshield is badly streaked from worn out blades polish out the streaks with toothpaste App
159. echnical service bulletin 23 034 00 Rev A dated December 15 2000 It is unnecessary to replace the entire outside rearview mirror assembly when the mirror glass is broken or is missing Replacement mirror glasses are available from Mopar Because of the extremely long list of part numbers involved please consult the Mopar parts catalog for the correct part number s Scratching sound from the door seal while driving Ascratching or itching type sound may be heard coming from the front door opening Ifa 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 EMISSIONS TSB 25 001 01 1 19 01 25 002 01 1 19 01 A Publication of the TURBO DIESEL REGISTER MODELS 01 BR BE 01 BR BE SUBJECT DESCRIPTION Generic Scan Tool May Not Display Certain DTC s and Erroneous LDP Switch This bulletin applies to vehicles with an RE automatic transmission built before January 12 2001 MDH 0112XX A generic scan tool may not display certain Diagnostic Trouble Codes DTC when a Malfunction Indicator Lamp MIL illuminates The PCM software must be updated to calibration level OlCall4A Scan Tool Erroneously Displays P000 For DTC s P1740 And P0461 This bulletin applies to vehicles with an RE automatic transmission built before January 31 2001 MDH 0131XX A Generic Scan Tool or an Enhanced Scan Tool l
160. ectrical connector The only serviceable parts on the module are the sending unit and the rollover valve and its grommet The sending unit is notorious for the wiper contact area to wear out which results in erratic fuel readings or fuel gauge malfunction A sender testing chart is shown should you desire to test your sender while the truck module is removed from the fuel tank Model Year Sender Sender Low fuel T a Ohms Ohms at Indicator PEAS at Full Empty Lamp ohms 94 97 0 100 65 98 02 20 220 PCM Function Sometimes the use of an old school analog multimeter will catch a dead or bad spot as the sender is moved up and down The needle will falter or jump at the contact failure Digital multimeters DMM are great tools but my old analog meter still gets plenty of use for tasks like this The DMM is constantly auto ranging for accuracy in a specific reading versus the analog meter holding a steady reading Now you have an excuse to purchase both types of multimeters Looking back in my TDR index see that members have been bothered by this problem since Issue 16 in the Spring of 97 when member Russell Caya did a how to on fuel tank removal Other memorable articles Issue 26 where Mel Lang took the sending unit apart in an attempt to understand why it was is problematic My look back at these old sources of information did not reveal a shadetree repair procedure Perhaps the lab
161. ed automatic transmission Maximum Towing Capacities Again in 2007 with the single power offering of 325 HP 610 ft lbs torque the GCWR towing capacities are simplified The numbers below are for regular Quad and Mega Cab trucks 2500 Manual or Automatic transmission with a 3 73 differential 20 000 2500 Automatic transmission 4 10 differential 20 000 3500 Automatic transmission 3 73 differential 21 000 3500 Automatic transmission 4 10 differential 23 000 3500 Manual transmission 3 73 differential 23 000 2008 Turbo Diesel What is New Introduced to the public in February 2007 at the Chicago Auto Show the Chassis Cab models 4500 and 5500 were officially known as 2008 model trucks These Chassis Cab trucks share the same powertrain as the 3500 truck that was introduced in March of 2006 For the 4500 and 5500 trucks the differentials are larger The front axle is made by Magna the rear axle is made by Dana Available gearing for the 4500 4 10 and 4 44 to 1 for the manual transmission 4 44 and 4 88 to 1 for the automatic transmission Available gearing for the 5500 4 44 and 4 88 to 1 for the manual transmission 4 88 to 1 for the automatic transmission Models Available Same as 2006 and 2007 2500 HD as standard cab quad cab with short bed or long bed in 4x2 and 4x4 configurations 3500 HD same as above although the dual wheel 3500 is not offered wiith a short box The Mega Cab is available in th
162. edure should only be performed on vehicles when R 12 is no longer available Odor from air conditioning ducts Some vehicles may emit a musty odor from the airconditioning ducts The odor is most noticable when the A C system is first turned on Two possible causes are discussed and repair procedure are outlined based on less than or greater than 12 months in service White flakes from instrument panel outlet Sodium silicate is used to coat the air conditioner evaporator for corrosion protection If excessive amounts are 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 A C evaporator odor A musty odor may be emitted from the air conditioner ducts The odor is most noticeable when the A C is first turned on after the system has been left off evernight or longer The odor is a result of foreign material accumulating in the evaporator area The bulletin involves cleaning and disinfecting the A C evaporator and housing A Publication of the TURBO DIESEL REGISTER CATEGORY 24 AIR CONDITIONING Continued 24 17 94 91 93 AD A C evaporation freeze up or lack of cooling on cycling clutch of air conditioning system 11 18 94 94 95 BR Loss of A C airflow and or cooling while the blower fan continues to operate may occur This bulletin discusses the role of the powertrai
163. eel disc brakes built before November 20 2000 Parking brake cable appears to be mis adjusted which may cause the parking brake lamp to remain illuminated even after the parking brake pedal has been released The parking brake system however is not mis adjusted and functions normally Install new parking brake cables CATEGORY 8 ELECTRICAL TSB MODELS SUBJECT DESCRIPTION 08 010 01 94 02 Airbag clock spring service 5 25 01 When servicing any airbag system it is essential to follow the proper Service Manual and or Diagnostic Manual 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 98 01 BR Exhaust manifold bolt retention straps 03 02 01 This bulletin applies to vehicles equipped with a 24 valve diesel engine built on or between engine serial number 56419738 and 56777585 with a date of engine manufacture from January 01 1998 to September 22 2000 This information is available on the engine data pl
164. el The noise is caused by the sheet metal joint between the A pillar and the dash pOanel plenum lower rubbing together The repair involves loosening that instrument panel and providing additional clearance between the A pillar inner panel and dash panel 23 25 00 97 01 BR Paint fogging whitening 06 30 00 Painted surfaces of the vehicle that are covered for extended periods of time with front end covers bras transit films or magnetic signs may appear to have a white milky spot on 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 60 A Publication of the TURBO DIESEL REGISTER TSBs Issued During 01 CATEGORY 2 FRONT SUSPENSION TSB MODELS SUBJECT DESCRIPTION 02 001 01 94 01 Rear of vehicle sits too high to allow hook up to a fifth wheel trailer 1 19 01 This bulletin applies to 2500 and 3500 4x4s The curb hight lowering package is designed to reduce the rear spring spacer block by 1 7 8 inch which will lower the rear of the vehicle by several inches proving clearance so that most customers can attach their fifth wheel or goose neck trailer to the trailer hitch turntable CATEGORY 5 BRAKES TSB MODELS SUBJECT DESCRIPTION 05 002 01 01 Parking brake pedal adjustment 3 9 01 This bulletin applies to 2500 3500 series Ram trucks with four wh
165. el tank The overly simplistic answer to a fuel pump failure is to return to your dealership for a warranty repair Have you exceeded the 36 000 mile or is it covered for 100 000 miles I don t know warranty period Labor for an in tank replacement will be expensive the aftermarket vendors listed for your 03 04 5 Third Generation brothers offer fuel transfer pump kits with sippy straws to bypass a failed in tank unit The price range is 450 and up depending on the pumps performance and whether or not you want additional filtration Robert Patton TDR Staff 117 118 5 2008 EPILOGUE ATTENTION 03 04 5 OWNERS As you may have noted had hoped that the May 2007 fuel transfer pump article would be the final word on what owners would need to do to make the different year model engines bulletproof Fortunately for the owners of 03 04 5 trucks there is an update to their story The article The Ongoing Fuel Transfer pump Saga is reprinted from TDR Issue 60 May 2008 So 03 04 5 owners and there are about 300 000 of you out there read on FROM ISSUE 60 THE ONGOING FUEL TRANSFER PUMP SAGA Or Why Subscribe to the TDR by Robert Patton Why subscribe to the TDR Cause the following can happen to you your family or your friends In a time of unknown you ll need a solution Here is the story Brother in law purchases your used truck Brother in law is in your big city and ventures downtown
166. ementioned electrical wires relays and cables to the side You will have to move the oil dipstick tube to the left and modify the bat wing to accept the new dipstick location 123 124 Relocate the oil dipstick tube to the valve cover 1 With one hand above and one hand below you can get to the fuel filter from above Modified bat wing with new dipstick location Once the fuel filter is removed following the Mopar Fleetguard directions is very easy The next several steps are from the instruction sheet e Ascrewdriver blade and an upward pry will enable you to pop the fuel filter from its plastic cartridge Remove the filter and inspect the filter and the cartridge for contaminants Likely the filter is discolored and is black in color No cause for alarm the filter is doing its job There is cause for concern if you find lots of junk in the plastic cartridge An accumulation of junk could indicate microbe activity in the fuel tank Draining the tank and treating the fuel system would be the necessary service technique e Discard the old parts e Confirm that the used end seal is removed from inside the head e Wipe clean the sealing surfaces of the new O ring and end seal inside the head e Install canister sealing O ring and confirm the end seal is in place on the canister e Lubricate the canister O ring with clean engine oil Do not pre fill the canister with fuel e Install to the point o
167. emove the 15mm nuts that you previously loosened and remove the transfer pump The three 15mm nuts that hold the fuel transfer pump in place 1 3 and 10 mm bolt holding the fuel line 4 Arrow 5 points to a fuel line that you have to remove with a 17 mm stubby wrench Step 6 Remove the supply from tank fuel line from the old transfer pump and reinstall loosely on to the new transfer pump Step 7 Reinstall the new transfer pump Reconnect wiring harness and the fuel lines the torque specification for the banjo bolts is 18 ft lbs Reconnect the supply line from the tank by pushing the line into the quick connect fittings Listen for the fittings to click Step 8 Purge air from the fuel system easier said than done This can be a long and arduous experience Turn the key to start the engine that is briefly turn the engine over Let the key come back to run Leave the key in the run position and listen for the fuel pump to operate It should run for 25 seconds Repeat this procedure at least four times before trying to start the engine Continue until the air is purged from the system It is normal for the engine to sputter and cough Step 9 Engine cranks You re finished Robert Patton TDR Editor FUEL PRESSURE GAUGES AND OPINIONS by Robert Patton Let s continue and discuss fuel pressure fuel pressure gauges and opinions To start lets look to Webster s dictionary for a definition Webster s opin
168. engine sales code ETH built on or after June 9 2005 through and including May 31 2006 The PCM software has been revised to address the following issues e AMIL may illuminate due to one or more of the following diagnostic trouble codes P0071 Inlet Air Temperature Sensor Rationality P0111 Intake Air Temperature IAT Sensor Rationality P0514 Battery Temperature Sensor Rationality P0191 Fuel Pressure Rationality e Turbocharger durability improvement Implemented an engine speed limitation when cold to protect the turbocharger bearings e Clutch durability improvement Implemented a minimum engine speed limitation when launching vehicle from a stop to protect the clutch This bulletin involves selectively erasing and reprogramming the PCM Cummins with new software 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 e Correction to oil pressure reading when engine is operating at higher engine temperatures above 195 F A Publication of the TURBO DIESEL REGISTER 85 CATEGORY
169. ent 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 03 DR Fuel filter water separator drain valve restriction 11 8 02 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 CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS SUBJECT DESCRIPTION 18 024 02 03 DR Incorrect dual wheel identification in VIN may effect replacement powertrain control module 8 12 02 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 iden
170. entosin CHF 7 1 or equivalent fluid for a car s power steering system Perhaps your experience as a new Turbo Diesel owner and its unique liquids is not unlike mine with the Volkswagen s mystery lubricants Care to explain the difference in the engine oil for a diesel versus the engine oil used in your car How about the New Venture 4500 five speed gearbox oil what makes it so unusual The NV5600 gearbox oil is yet again different The G56 gearbox oil is different too Friction modifier fluid for the differential where do find such a product Automatic transmission fluid specification ATF 7176 4 sounds strange to me Anything special needed for antifreeze Brake fluid Power steering fluid Special lubricants for your vehicle A Publication of the TURBO DIESEL REGISTER Do my new car experiences parallel your experience with the new ownership of your Turbo Diesel truck Can we take these frustrations and make them into an opportunity to learn You bet Let s start with the lubricant that gets changed with the greatest frequency the engine s lube oil FIRST THING TO NOTE YOUR OWNER S MANUAL Yep time to issue the editorial disclaimer The authoritative source for this article is the Owner s Manual from my 99 2500 Turbo Diesel Specifications do change and you should use the products listed in your manual Our article is an effort to clarify and thus help you find readily available lubricants Also our article is wr
171. epair involves removing windshield spacers at the base of the windshield 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 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 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 94 BR Cup holder rattle If cup holder rattles in the closed position add a foam block to the back of the mug holder 94 95 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 94 BR Tailgate hard to latch in cold temperatures If the tailgate is difficult to latch wnen 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 A Publication of the TURBO DIESEL
172. eplacement of future ECM s will require programming utilizing the DRBIII and TechCONNECT CATEGORY 19 STEERING TSB MODELS SUBJECT DESCRIPTION 19 003 02 97 02 BR BE Hissing sound coming from the power steering system on vehicles equipped with hydroboost 4 15 02 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 19 005 03 94 02 BR BE Power steering fluid usage 8 29 03 02 04 DR 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 A Publication of the TURBO DIESEL REGISTER 13 CATEGORY 23 BODY TSB MODELS SUBJECT DESCRIPTION 23 018 02 00 01 BR BE Armrest lid difficult to open 5 20 02 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 0
173. erdrive once the ambient temperature has risen approximately 7 above the temperature the ID was inhibited at 94 BR with Transmission shift lever stuck in or blocked out of 5th gear reverse manual transmission The shift lever does not shift out of 5th or reverse gear position or the shift lever will not go into NV 4500 HD 5th reverse Diagnose the transmission and if necessary replace the transmission overdrive rail lug shift fork and synchronizer 94 BR with Shift lever contacts instrument panel manual transmission Inspect the shift lever to transmission stub shaft connection Reseat the lever to the stub shaft NV 4500 HD if necessary 94 BR 93 AD with Transmission diagnostic reference supplement automatic To assist in the repair of automatic transmission the information only bulletin lists symptom cause transmission correction information 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 94 95 BR with Shift linkage adjustment automatic trans The information only bulletin explains how to correct a PRNUL misalignment 94 94 BR with High effort when shifting from 2WD high to 4WD high in cold temperatures NP 241 HD transfer If high effort condition occurs when shifting the transfer case in cold temperatures the bulletin case describes the repair The proce
174. ere are several things to watch for when servicing your fuel filter The spin on cartridge used in 94 to 96 vehicles Fleetguard FS1253 has three o rings that require attention when installing the filter one on the re usable water in fuel sensor one that contacts the filter base and also one that fits onto the filter nipple It s not a bad idea to check that the filter nipple is tight in the filter base with a hex wrench Fuel Filter 1994 1996 1997 1998 Drop in cartridge Filter cartridge canister housing contains a fuel drain and WIF sensor Spin on cartridge w removable fuel drain WIF water in fuel sensor On the drop in style cartridge used in 97 and 98 vehicles Fleetguard 19578 the o ring on the canister housing s threaded shaft just below the brass bushing is sometimes omitted from a filter kit Should that be the case it is an acceptable practice to reuse the existing o ring The fuel then travels from the filter outlet to the Bosch P 7100 fuel injection pump This concludes the delivery portion of the tour of the low pressure fuel system However several other items are worth mentioning on the return circuit of the fuel system On the backside of the injection pump near the front corner of the pump is the location of the Bosch P7100 fuel pump overflow valve This valve opens and allows fuel return to the fuel tank at approximately 22psi When diagnosing fuel pressure problems one ca
175. es Gary K7GLD Canyon City OR Glitch My truck smells like a refinery Owners of 24 valve trucks reported a heavy oil smell coming into the truck cab caused by the crankcase breather tube venting the smell particularly after an oil change into the air stream of the engine fan especially when sitting at a stoplight with the heater or air conditioner running and the cab fan on The vent fan sucked the smell into the cab air intake at the windshield base Fix Extend the crankcase breather outlet toward the rear of the engine out of the engine fan air stream Dodge offers an engine oil that lacks the aromatic compounds that cause the objectionable smell Other ways to cure the heavy oil smell are to drive the truck only in warm weather and to use used lube oil when you do an oil change Say what During the winter months the air is colder and the diesel exhaust fumes and oil breather fumes hang low to the ground Thus an explanation for the noticeable smell in the winter months But used oil Seriously there is a Dodge technical service bulletin TSB 09 02 00 134 page 99 that addresses the heavy oil smell The odor condition is a result of certain diesel oil additives and the odor reduces in intensity as the oil ages The aging process typically takes place in 250 to 750 miles after the oil change Used oil anyone Glitch The truck started but the starter won t stop Fix Worn and pitted starter solenoid contacts wi
176. es DTC s B166B Left Trailer Tow Lamp Control Circuit Low Trailer harness left lamp circuit is shorted to ground B166C Left Trailer Tow Lamp Control Circuit High Trailer harness left lamp circuit is shorted to battery voltage B178C Left Trailer Tow Lamp Control Circuit Over Current Trailer harness left lamp circuit is intermittently grounding B166F Right Trailer Tow Lamp Control Circuit Low Trailer harness right lamp circuit is shorted to ground B1670 Right Trailer Tow Lamp Control Circuit High Trailer harness right lamp circuit is shorted to battery voltage B166E Right Trailer Tow Lamp Control Circuit Over Current Trailer harness right lamp circuit is intermittently grounding B1667 Back Up Lamp Feed Low Trailer harness back up circuit is shorted to ground B2215 Front Control Module Internal TIPM An internal fault code counter has exceeded its limit of 250 counts and one or more electrical outputs controlled by the TOPM have been disabled P1277 Starter Control Circuit 2 Low TIPM The output feed current to the starter solenoid has exceeded the upper current limit of 75 amps This may result in a no crank condition DTC s B1667 B166B B166E B166F B178C and B2215 These DTC s indicate that a hard or intermittent short circuit to ground exists in the wiring of one or more of the trailer electrical harness circuits The TIPM retries the output on each ignition cycle or request brake or turn signa
177. et 23 09 96 96 BR Seatbelt buckle difficult to engage with one hand 2 2 96 Clubcab with a J in The driver side power seat may have a seat belt buckle that may be difficult to latch The repair the VIN at position involves replacement of the seatbelt buckle 11 and built prior to 10 6 95 23 21 96 94 96 BR Tailgate difficult to close in cold weather 3 29 96 At less than 5 F the tailgate latch stop bumper may be too stiff to allow for easy closure Inspect and replace bumper stop 23 27 96 96 BR Windnoise whistle around grille area 4 19 96 If vehicle exhibits a windnoise whistle at speeds of 45 to 85 mph the diagnosis involves checking the grille for a manufacturing code CAV3 If there is not a CAV3 stamp than the grille is not likely the source of the noise If noise is from the grille the repair involves adding 1 4 foam tape between the grille and hood 23 29 96 94 96 BR Tailgate cracking on top inner ends 5 10 96 Some vehicles may exhibit a sheet metal crack along the top inner ends of the tailgate The bulletin describes the parts and the correct repair procedure 23 45 96 94 96 BR Instrument panel creak 8 2 96 This bulletin supersedes TSB 23 57 93 8 8 93 A creak or squeak may be present on the left or right side of the instrument panel The noise is caused by two sheet metal parts rubbing together The repair involves loosening the instrument panel and providing additional cle
178. f first contact for canister flange and head e Tighten the canister an additional 1 2 turn of rotation e Reconnect the WIF sensor electrical connection and ensure proper connection is made e Reinstall the drain hose It is now time to re prime the fuel filter canister With the key in the ignition briefly bump the starter but don t attempt to crank the engine Let the key fall back to the run position Listen for the electric fuel transfer pump to operate It should hum for about 20 seconds The transfer pump is located in the fuel tank so you ll have to either carefully listen or have someone crawl under the truck and listen Repeat this bump and prime procedure four or five times Now the moment of truth Crank the engine and let it run for 20 30 seconds Check the filter area and confirm that no fuel leaks are present Restart your engine and you are good to go for another 15 000 miles Robert Patton TDR Writer A Publication of the TURBO DIESEL REGISTER THE HARVEY BARLOW METHOD Those that frequent the TDR s web site are likely familiar with Harvey Barlow and his helpful post in the 6 7 liter area of the discussion forums In early August Harvey discovered another and perhaps easier way to change the 6 7 liter fuel filter The following is Harvey s method Using this do it yourself tip it is not necessary to remove the left front tire or even the left front fender inner lining As Patton suggests you may w
179. f the tested boxes the power was smooth and predictable As for actually measuring low side fuel pressure we hooked up the boost channel of the SPA Technique EGT boost gauge to an SPA pressure sender on the Bosch CP3 fuel pump inlet For the most aggressive power increase we tested the low side fuel pressure dipped to a value that is nominally equal to atmospheric pressure gauge pressure read zero This means that the low pressure fuel system is at the limit of its capacity and from this we concluded that for the power levels tested the low pressure fuel system was sufficient although barely so Zero gauge pressure simply means that the CP3 inlet is not drawing or pulling fuel under vacuum Okay should you spend money on a gauge to tell you that the truck is not starting Will you be increasing the engine s output by a number larger than 100 horsepower can t answer these questions for you can suggest a combination of parts a fuel cap and a Westach gauge to make the installation on a 03 and newer truck easy to do Go forth and make an informed decision 113 114 24 VALVE TRANSFER PUMP RELOCATION KIT In August 05 TDR writer Andy Redmond wrote in to tell about a Mopar retrofit kit for the fuel transfer pump used on 798 5 to 04 5 Turbo Diesel pickup trucks The following are the highlights from Andy s e mail At the conclusion of his discussion I ll offer my opinion of the kit Robert here are the highlig
180. failed engine start run solenoids frayed throttle cables hard start due to degradation of the rubber fuel return line automatic transmissions problems that were often caused by fluid loss at transmission line to cooler line to transmission quick couple plastic fittings poor fuel filter access loss of fifth gear in five speed transmissions failed front end parts on 4x4 models poor front brake pad life in certain applications poor paint adhesion of certain colors failure of throttle position sensors on automatic trucks and faulty fuel level sending units Common Problem areas 1998 5 to 2002 Included failed fuel transfer pumps and fuel injection pumps weak clutch on six speed trucks poor front brake pad life in certain applications and poor front suspension bushing life on 4x4 models FROM THE DATA BOOKS The following information was compiled using DaimlerChrysler data books Actual production may be slightly different especially if a particular truck was produced near the beginning or end of a particular model year run We will start with the 1994 model which is the first year of the current body style For each model year we will note what s new models available engine ratings transmissions maximum tow ratings cab chassis models and comments ie I i saie e O tey ee HEC dr This interesting phot is an early 94 model truck that was modified to run at Bonneville It successfully set a class record at the 1
181. fasteners or with steel fasteners in aluminum Better yet purchase an impact screwdriver to properly loosen those stubborn fasteners If you are trying to install a screw in an inaccessible place tape the screw to the screwdriver point insert the screw in its hole and turn it in The tape will eventually fall off A dab of grease or body putty may hold a light screw the same way Want to prevent a fastener from rusting after it has been installed Simply coat the head with clear nail polish Clear nail polish also works as a thread locker Coat the threads then quickly install the fastener For removing rusty nuts and bolts always use penetrating oil first and let it soak a bit before trying to break them loose If you re trying to fish a part or fastener out of an inaccessible place simply wrap some duct tape sticky side out around the end of a straightened coat hanger It may take a couple of tries but if the tape will stick to the part the part will come out with the coat hanger This works better than a magnet if you are working in an area full of metal Ever tried to hold a nut in a tight spot while threading a bolt into it Wrap a fingertip with duct tape glue side out or make a loop of the tape to stick it to your fingertip then place the nut on the tape The nut will stay put and not rock around while starting the bolt threads 135 136 ELECTRIC TIPS When taping a bundle of wires together coat the tape en
182. fic vehicle you may want to buy consult your list again to make sure it meets all criteria First on your to do list following a second general walk around inspection and a ride and drive session of a particular truck should be some research to find out who the former owner was and initiate a conversation If you re buying from a dealer ask the owner what the mileage was at turn in time and on what date the vehicle was turned in If the truck has been in a dealer s possession for a while has it been used for hauling chores with no maintenance Have other potential buyers shied away from it for some reason not readily evident Find out why Ask the former owner what maintenance has been performed and when and if the truck has been wrecked What was it used for Was it satisfactory for that use If the owner has maintenance records arrange to pick them up if you buy the truck Finishing Up You ve done the research negotiated the price and now itis time to exchange dollars for the vehicle The job s not done until the paperwork is finished and the paperwork had better be right If buying from a dealer you should receive a bill of sale and certification of the odometer reading along with several other pieces of paper which will vary by state Usually the dealer will apply for a new title in your name If buying from a private individual you should receive a clear title signed over to you by the owner You will then take t
183. flected in the Service Manual and a future release will outline service procedures 03 002 02 02 03 DR Use of synthetic rear axle lubricant 7 1 02 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 4 rear axle on 2002 2003 DR Ram trucks the axle must be refilled with Mopar 75W 140 synthetic gear and axle lubricant PN 04874469 Five ounces 148ml of Mopar friction modifier PN 04318060AB must also be added to vehicles equipped with the trac lok style rear axle CATEGORY 6 CLUTCH TSB MODELS SUBJECT DESCRIPTION 06 001 03 03 BR Rattle sound from transmission when idling 5 16 03 This bulletin applies to vehicles equipped with a 5 9L Cummins high output Turbo Diesel sales code ETH and NV5600 six speed manual transmission sales code DEE built on or before May 11 2003 The vehicle operator may describe a rattle sound when idling in neutral with the clutch pedal released The bulletin involves replacing the clutch disc with a revised part 70 A Publication of the TURBO DIESEL REGISTER CATEGORY 8 ELECTRICAL TSB MODELS SUBJECT DESCRIPTION 08 016 02 02 03 DR Horn chirp and erroneous alarm 9 2 02 This bulletin involves reprogramming the forward control module FCM should there be an erroneous horn chirp when a door is opened or an err
184. formance until coolant temperature reaches 170 The repair involves erasing and reprogramming the Cummins ECM with new software 18 004 04 04 DR Poor cab heat and or slow engine warm up in cold ambient temperatures 2 3 04 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 04 DR White smoke engine stumble misfire or flat spot in engine performance 2 24 04 This bulletin applies to vehicles equipped with a Cummins Turbo Diesel engine sales code ETH with an engine serial number 57130285 through and including 57149668 and the engine date of manufacture 12 10 2003 through and including 2 2 2004 The vehicle operator may describe e White smoke during no load engine acceleration between 2800 and 3000 rpm e Engine stumble misfire or flat spot during moder
185. fuel heater Remove the two mounting bolts Remove the fuel pump and fuel heater as one unit Be careful not to allow the plunger to catch on the edge of the hole in the cylinder block and drop into the engine As intimidating as this sounds you would have to try to do this as the plunger has to be pulled from its bore Simple enough Carter lift pump with plunger removed 109 110 Helpful Hints Instead of removing the starter motor decided to get really acquainted with my engine and come in from the top of the engine compartment This appeared easier than trying to work around the front differential to remove the heavy bulky and greasy starter The only problem is that when you try to reinstall your fuel pump and fuel heater unit you cannot push the pump back into place because your arms are not long enough to get any leverage to push the plunger against the camshaft This is the voice of experience and about an hour of labor and an evening in the easy chair thinking about the problem speaking to my fellow TDR members Learn from my situation that there is a simple solution thus making the top removal a practical service technique Carter lift pump with regular mounting bolt and longer temporary bolt Here is the secret When you remove the fuel lift pump take one of the two mounting bolts and find a replacement that is the same metric thread size but about 3 4 longer You probably have one in your parts box or y
186. g between gears Do the brakes pull to one side Does the truck steer correctly While driving note if there is excessive smoke from the exhaust Black smoke indicates overfueling or a clogged air filter White or gray smoke indicates excessive oil getting by the piston rings or an injection pump problem A puff of smoke of any color at startup is normal but should abate when the engine warms Walk around the truck immediately after the ride and note any smells of hot dragging brakes or leaking fuel A hot oil smell can indicate an oil leak onto the exhaust system Don t be embarrassed to ask to put the truck up on a lift for a more thorough inspection or to take the truck to a trusted mechanic for a professional inspection A professional independent inspection for a fee is cheap insurance that you are making a wise purchase decision After you are fully satisfied that the truck is what it is represented to be move on to the next step Contact the Owner There are many possible reasons why this particular truck came to be for sale and it is up to you to determine the true reason Is the owner financially able to afford a new vehicle with more fancy gadgets or was the owner tired of fixing a A Publication of the TURBO DIESEL REGISTER problem or problems repeatedly Is the owner simply selling a vehicle that is no longer needed It is up to you to find out When you find a likely candidate and your search narrows to a speci
187. g or deteriorated Using the diagnosis as outlined in the 97 Service Manual determine the cause of the inoperative speed control Perform the repair as outlined in the bulletin 08 27 97A 97 BR Inoperative CD player as a part of sales code RAZ radio 9 26 97 This bulletin supersedes TSB 08 27 97 dated 7 18 97 The bulletin applies to 97 vehicles equipped with an AM FM cassette CD player sales code RAZ radio A condition is described where the CD player may become inoperative and will not accept the CD when attempting to insert the disk into the radio The condition can be intermittent and may occur more often in hotter ambient temperatures The AM FM radio and cassette portion of the radio will continue to operate normally The repair involves an exchange of the unit as supplied by Chryslers repair center 08 30 97 98 BR Ashtray receiver lamp degrades from blue green to bright white 9 5 97 The ash receiver lamp when illuminated may change from a blue green illumination to a bright white illumination This 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 94 98 BR NHTSA authorized airbag deactivation for medical necessity 9 19 97 This information only bulletin describes the procedures necessary to deactivate airbags authorized by NHTSA Airbag deactivation is a customer pay procedure not covered under the p
188. gear coming unpinned from the mainshaft A revised nut and crush washer have been developed to cure this problem along with a 14 page Dodge Factory Tech Service Bulletin outlining the proper repair procedure and special tools needed Trucks equipped with the five speed manual transmission are prone to excessive gear lash in the driveline This can cause hard jerking when the throttle is suddenly lifted particularly when hauling or towing heavy loads This condition is normal In addition to gear lash the rubber bushed drivetrain windup is partially responsible Draining and refilling the automatic transmission oil pan is not fun for the backyard mechanic because the pan cannot be drained before removal B amp M offers a drain plug that can be inexpensively installed in the pan to make fluid and filter changes easier and cleaner The plug is available from Geno s Garage In vintage 94 to 98 trucks with automatic transmissions cooling lines have plastic quick disconnect couplers that can fail under high heat conditions causing a loss of transmission fluid A revised coupler is available from Dodge parts Or you can make your own using weatherhead brass fittings of the appropriate size available at most auto parts stores The fittings are listed under the trade name Dana Weatherhead 68x8x4 Caution we have seen reports that the hard fittings can cause stress cracks in the transmission line due to vibration When
189. ght that the revised electric fuel transfer pump for these trucks was a better design than the 98 5 02 pump Well brother in law s transfer pump lasted 115K miles Armed with information in the TDR and a 180 towing bill the brother in law has some new found options Postscript to the Issue 56 article Page 74 03 04 5 What to do As you ve previously read the Mopar and Cummins parts networks have deleted the replacement fuel transfer pump from their inventories Issue 56 was written in April 07 At that time the only plug and play option was a part number FP943 that was offered by Delphi at a retail price of about 450 Since that time we have found that the FP943 pump is made by one source the same source that made the pump for Mopar and Cummins Carter division of Federal Mogul can only imagine their surprise when Mopar and Cummins scrapped out their inventories last spring Lots of extra inventory Perhaps so The same part is not only showing up in a brown Delphi box it is now available in a white Fel Pro box Weve closely inspected the pump and its contents They are the same And available in stock More good news the price has substantially dropped How about less than 200 For those that want a plug n play option or spare part there is availability at several vendors Diesel Injection Scheid diesel and Geno s Garage are locations that am aware of So 03 04 5 owners it is time
190. gned to reduce white smoke and improve engine performance after a cold start at ambient temperatures below 60 F and to improve oil pressure gauge operation 06 07 DR DH D1 StarSCAN StarMOBILE abort recovery procedures 07 DC 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 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 e Engine fan is activated if the coolant temperature sensor fails e Enhanced battery charging This bulletin involves flash reprogramming the PCM Cummins with the software 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
191. gs Same as 2007and 2008 In consumer pickup models 2500 and 3500 350 HP and 650 ft lbs of torque with the automatic transmission and 350 HP and 610 ft lbs of torque with the manual transmission The engine ratings for the Cummins 6 7 liter engine in the Chassis Cab models 3500 4500 and 5500 remained the same when the engine was introduced in 2006 305 HP and 610 ft lbs or torque Engine Changes for 2009 Starting in 02 the heavy duty trucks introduction has followed the Dodge Ram 1500 by one year The model year 2009 heavy duty trucks are no exception they continue with the same cab and chassis design As you can expect there are only a few subtle changes to the engine These changes are e Access port on the turbocharger s exhaust housing that allows for exhaust turbine cleaning as needed e Revised stamped steel alternator bracket e Revised coolant hoses and O ring fittings for the plumbing that goes to cool the exhaust gas recirculation heat exchanger e Revised fuel filter assembly that features a dual filter with greater filter area to strip away water as well as a secondary fuel filter with a smaller 5 micron rating The current fuel filter is 7 micron The new fuel filter was released for production in January and the part can be retrofitted to the 07 5 to early 09 engines Service parts for these engines will likely be released in May e Revised water inlet housing Transmissions In the consumer pi
192. h paper towel or sponge e Return the wiper blades to their normal operating position If the wipe pattern is still objectionable repeat several times If the wipe pattern is still objectionable replace the wiper blades elements 23 018 06 06 DR Speaker buzz 5 5 06 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 04 07 DR Transit film removal 01 26 07 This information only bulletin provides a transit film removal procedure 23 021 06 07 DR YES Essentials stain odor and static resistant fabric care Rev A This bulletin applies to vehicles equipped with YES Essentials stain odor and static resistant 08 09 06 fabric sales code XGW YES Essentials fabric is an easy care material that repels and releases soil to maintain the like new appearance Spills remain on the surface of the fabric to allow for easy clean up and to prevent stains and odors The material is antimicrobial and static resistant YES Essentials fabric may be cleaned in the following manner e Remove as much of the stain as possible by blotting with a clean dry towel e Blot any remaining stain with a clean damp towel e For tough stains apply Mopar Total clean p m 04897840AA or a mild soap solution to a clean damp cloth and remove the stain Use a fresh damp towel to remove the soap residue e For grease stai
193. hange CATEGORY 22 WHEELS TSB MODELS SUBJECT DESCRIPTION 22 001 01 00 01 BR BE Chrome wheel care Rev A Chrome wheels should be cleaned regularly with mild soap and water to maintain their luster and 9 28 01 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 Acar wash that has carbide tipped wheel cleaning brushes MMMM Mm Mmmm 68 A Publication of the TURBO DIESEL REGISTER CATEGORY 23 BODY TSB 23 027 01 9 21 01 23 034 01 11 30 01 MODELS 98 02 BR BE Equipped with 6x9 Mirrors Sales Code GPS or GPU 00 01 BR BE CATEGORY 25 SUBJECT DESCRIPTION Outside rearview mirror glass replacement This bulletin supersedes t
194. hange the NV4500 s gearbox oil every 30 50 thousand miles depending on load Use 75W 90 GL 4 or 80W 90 GL 4 rated synthetic oil Chrysler part number 4874459 or Castrol Syntorgq Often members will ask about the GL 4 rated Castrol synthetic gear lubricant 75W 90 If the GL 4 classification is good shouldn t a GL 5 rated lubricant be better In the case of the NV4500 gearbox not necessarily so The GL 5 oil uses twice the amount of sulfur phosphorous additive package as GL 4 At high temperatures the phosphorous plates out and reduces the coefficient of friction of the synchronizer rings New Venture Gear has seen this on shift stand tests Since there s twice as much of it there s more of a detrimental effect compared to GL 4 Although it does not affect the NV4500 the additional sulfur content of GL 5 attacks brass Like the Volkswagen saga the GL 4 rated Castrol Syntorq lubricant is difficult if not impossible to find at the local auto parts store Thankfully there are advertisers in the TDR Standard Transmission and Gear comes to mind they sell the Syntorq in and one gallon quantities 800 783 8726 that have this lubricant for resale 2001 2005 Six Speed NV5600 Manual Transmission To quote from the Owner s Manual This transmission is filled with manual transmission fluid at the factory This fluid does not require periodic changing If it is necessary to add or change the fluid in this transmission us
195. he title to your vehicle registration place to get a new title in your name Either a bill of sale from a dealer or a signed title from the owner should be placed in your hands at the time you give them your check no exceptions and no excuses by the seller Remember the job s not done until the paperwork is right Make sure the serial number on all paperwork agrees with the serial number stamped into the left front corner of the dashboard Paperwork mistakes in this area are frequent and hard to correct later Before driving your new purchase home call your insurance agent to insurance Failure to do so could have disastrous consequences just down the road Finally if there is any remaining warranty on the vehicle be sure to fill out and send in the paperwork to get it transferred to you If the truck is less than five years old and has less than 100 000 miles on the odometer you should transfer the remaining engine warranty That s it You now own your new to you truck and if you have researched fully and purchased carefully you ll have many miles of enjoyable cruisin ahead of you Jim Anderson TDR Writer 22 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
196. he Chassis Cab gets the 6 7 liter Cummins engine rated at 305 HP and 610 ft lbs torque Transmissions Consumer pickup models 2500 and 3500 no changes from 2005 Commercial Cab and Chassis 3500 G56 six speed manual transmission same as consumer pickup Aisin AS68RC six speed automatic transmission The Aisin internal gear ratios are as follow Aisin AS68RC 1 2 3 4 5 6 3 74 2 00 1 34 1 00 TT 63 Differential Ratios Offered 3 73 and 4 10 to 1 Both the 3 73 and 4 10 are offered in consumer pickup models 2500 and 3500 In the Chassis Cab model 3500 both the 3 73 and 4 10 are available with the G56 manual transmission The 4 10 is the only axle ratio offered with the Aisin AS68RC automatic transmission Maximum Towing Capacities With the single power offering of 325 HP 610 ft lbs torque the GCWR towing capacities are simplified The numbers below are for regular Quad and Mega Cab trucks 2500 Manual or Automatic transmission with a 3 73 differential 20 000 2500 Automatic transmission 4 10 differential 20 000 3500 Automatic transmission 3 73 differential 21 000 3500 Automatic transmission 4 10 differential 23 000 3500 Manual transmission 3 73 differential 23 000 Chassis Cab Models Introduced in March of 2006 the Commercial Chassis Cab trucks are initially available as a 3500 series truck The 3500 series truck is available in single or dual rear wheels SRW DRW The truck is available
197. he old 8mm hardware with new 10mm hardware Installation is in reverse of removal Check the length of shaft on the solenoid it should be 2 64 inches from the top of the lever pin to the bottom of the bracket The new solenoid linkage comes preset and tightened so you should not have to adjust the linkage but if the linkage has been misaligned you will have to loosen the shaft locknut and rotate the adjuster to the correct length Just by following Joe G s easy steps was able to save myself a lot of money and a lot of hassle Overall the replacement took about thirty minutes and was a fairly easy job skill level 2 Just the job for the do it yourselfer Hopefully next time will get to write about something that was not broken Brandon Parks Geno s Garage Editor s note In a previous life owned a 96 Turbo Diesel had the same no start need to replace something problem with either the relay or the solenoid Brandon didn t mention but if a no start condition occurs one of the first things you should check is the movement of the solenoid linkage If the pull up coil doesn t work no matter the reason wiring relay solenoid with the key in the on position reach below the rod and push it up Now drive on to your destination and troubleshoot the problem as time permits Likewise if you turn the key off but the solenoid doesn t release the engine will keep running Time to push the solenoid lever down and the engine
198. he 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 CATEGORY 9 ENGINE TSB MODELS SUBJECT DESCRIPTION 09 004 06 03 06 DR Accessory drive belt chirp at shut down 03 31 06 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 CATEGORY 11 FRAME BUMPER TSB MODELS SUBJECT DESCRIPTION 11 002 07 07 08 DH D1 Inspection and test procedures for the 6 7 liter diesel particulate filter DPF 9 25 07 2500 3500 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 de
199. heel on the fresh air side of the turbocharger known as the compressor The compressor wheel blades draw filtered air into the compressor housing raising the air s density and pressure as the air is forced into the engine More air mixed with more fuel equals more power As you add air fuel to the engine it makes more power The temperature and flow of the exhaust gas increases With the increased exhaust flow and temperature the exhaust pin wheel turbine spins faster Thus the intake pin wheel compressor pressurizes boosts more air into the engine More air fuel to the engine makes more power creates additional exhaust flow and temperature Get the picture BOOST DIAGNOSTICS How can we use the engine s boost to diagnose engine performance There are specifications for boost for the various engines which have been and are in current production Keep in mind that it takes fuel and air to make power and boost If the engine meets the boost specification the power is there and it passes the Boost Treadmill test At this juncture itis tempting to generalize the data However I ll avoid the temptation and research the boost specification for a given engine build or in Cummins speak control parts list CPL The Cummins CPL is anumber that spells out key components fuel pump settings turbochargers cylinder heads pistons etc used in the engine The following detailed table presents the data
200. hen read the size of the wrench MECHANICAL When installing a gasket that refuses to stay in place during installation put a light coat of chassis grease on the gasket s undersurface then stick the gasket to the metal It will now stay in place during assembly Put a light coat of chassis grease on the gasket s undersurface then stick the gasket to the metal 137 138 Lube and service basics for your new truck Always follow the recommendations in your Owner s Manual Below are excerpts from the manual and further TDR commentary Breaking in your new truck Drive moderately for the first 1 000 miles to assist in breaking in the powertrain brakes bearings etc Do not use full throttle for extended periods and vary speeds frequently After the first 1 000 miles use the truck normally Particularly during the breaking in period avoid extended idling Your Cummins engine will break in faster if you haul or tow with the truck The engine will not be fully broken in and will not reach its full power and fuel mileage potential until it has operated for approximately 10 000 miles Fuel Use only 2 diesel fuel As an option in winter you may use 2 diesel fuel blended with 1 diesel or kerosene or 2 diesel otherwise treated to lower the pour point of the fuel Use 1 diesel fuel for extreme cold weather operation only Always fill at popular locations that sell a lot of fuel Diesel that has not been subject to long storag
201. hen shifting from one gear to another between 2500 and 3500 RPM after a cold start up This condition is most evident when ambient temperatures are at or near 0 C 32 F but can occur at warmer temperatures as well The condition is most often reported on 3 to 4 gear shifting but can occur in the other shift ranges as well The problem can be verified by assuring the transmission is at ambient temperature vehicle moving and with the engine at 2500 to 3500 RPM shifting into and out of the gear ranges This repair may include disassembly of the countershaft assembly requiring the use of a 20 ton press Attempts to use lesser equipment to effect this repair could result in damage or injury If such a press is available rebuilding the countershaft assembly is preferred In the event a press is not available a new countershaft assembly PN 05073361AA has been made available Follow the service procedures in the appropriate service manual to complete necessary repairs Follow normal warranty procedures to report the repairs A Publication of the TURBO DIESEL REGISTER 67 CATEGORY 21 TRANSMISSION Continued 21 006 01 94 02 BR BE Automatic transmission fluid usage ATF 4 Type 9602 6 29 01 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 vehi
202. her low level light situation David Burton 9 ENGINE If you need to turn the engine over to locate Top Dead Center of a cylinder and lack the special tool to do this job use a 22 mm socket wrench on the alternator pulley nut Turn the engine backwards from its normal rotation backward rotation for servicing is not a concern to keep the pulley from slipping on the belt Or put a socket on one of the crankshaft damper nuts and have an assistant turn the engine over from underneath the truck Member Ed Wash of Alaska wrote in to ask for a solution to oil dripping from the plastic pipe road draft tube under his engine It is normal for a drop or two to come from this tube when the truck has been parked overnight A member solved the same problem by drilling a 1 1 4 hole in the lid of a large Rolaids jar and drilling eight holes around the top of the jar body Drill a horizontal hole at the bottom of the draft tube Slide the lid over the hose and secure the underside with a tie wrap Screw the jar onto the lid It stops the drips Keeps the driveway spotless If you have trouble reading the oil level dipstick without your glasses put the dipstick in a vise and file a V notch in the side of the stick at the full mark and one at the add mark Makes it much easier to read the oil level accurately Steve Richards Use a Sidewinder ratchet wrench available at many chain auto parts stores for fuel filter removal wi
203. hich is located on the left side of the engine affixed to the side of the timing gear housing 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 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 89 93 AD Engine lubricant 94 01 BR BE This bulletin involves 1989 2001 Ram trucks equipped with the 5 9L Cummins diesel engines This bulletin discusses
204. hicles Speed control over undershoot during set of speed selection The bulletin discusses the adaptive strategy that compensates for vehicle to vehicle variations in speed control cable lengths Pressing the set button without pressure on the accelerator pedal can cause speed fluctuations Proper review of the condition with vehicle operator is recommended Poor AM radio reception Tighten the antenna base to 70 in Ibs to assure reception Infinity radio code RAY looses sound on right channel speakers Infinity RAY cassette with equalizer system may loose the sound of right side speakers RAS code radios are not affected An exchange radio is the repair Weak sounding horn The bulletin discusses an upgrade from a single horn to a dual horn system Fuel gauge sticks The bulletin covers replacing the fuel pump module if the fuel gauge intermittently sticks at full with less than full capacity Battery drain on vehicles equipped with trailer tow package Water may collect in the 7 pin trailer tow connector housing causing corrosion Exterior or interior lights may erratically operate regardless of switch operation Inspect the tow connector and notch the connector to allow for drain Diesel secondary battery does not charge vehicles built prior to 2 14 94 Corrosion at battery clamp to secondary battery may prevent charging Inspect test and replace battery clamp bolt if necessary Fuel gauge
205. hicles may contact the exhaust pipe Under certain operating conditions the exhaust pipe may become not enough to over heat or ignite the silencer pad To correct this condition part of the silencer pad must be removed and a heat shield must be added to the exhaust pipe Models 1997 model year Dodge Ram BR trucks equipped with a 5 9L diesel engine D in the 8 VIN Position built at the Saltillo Assembly Plant G in the 11 VIN Position from March 7 1997 through May 15 1997 St Louis North Assembly Plant J in the 11 VIN Position from March 15 1997 through May 16 1997 Lago Alberto Assembly Plant M in the 11 VIN Position from March 18 1997 through May 15 1997 The service repair procedure involves removal of a portion of the silencer pad and the installation of heat resistant foil tape to the remainder of the silencer pad and the installation of a heat shield onto the exhaust pipe IGNITION SWITCH WIRING RECALL 875 The ignition switch and or steering column wiring may overheat when the blower motor is operated at high speed for an extended period of time This can cause stalling loss of blower motor or power window operation ABS or airbag lamp illumination or a steering column instrument panel fire The vehicles involved in the recall have a vehicle identification number as follows Warren S in the 11 VIN position through April 4 1996 St Louis J in the 11 V
206. how to perform And as recently as the 98 model year air and an accompanying squirt of diesel fuel had to be vented using the manual fuel lift pump purging the air from a bleed screw With the 98 5 24 valve engine s electric fuel lift pump and self venting fuel system the bleedscrew squirt of diesel problem went away However the I don t know how intimidation factor remains As with the 98 5 02 and 03 07 trucks owners of 2007 5 and newer trucks have a fuel filter system that has an electric fuel lift pump and is self venting For 98 5 and 99 owners the fuel filter how to was covered in Issue 25 pages 84 86 For 00 07 owners the how to was in Issue 45 Now that we have established the need for fuel filter maintenance Let s get started on the how to section of this article for the newer 07 5 audience A Publication of the TURBO DIESEL REGISTER 2007 5 and Newer Fuel Filter Change First let s present three tips that will save you time and aggravation e Purchase your fuel filters in quantity This prevents the excuse that you could not change the filter due to a not in stock situation Additionally a spare fuel filter should be in your box of emergency parts that you carry inside the truck You cannot predict when or where you might receive a bad fill of fuel e Extend the fuel drain hose The existing drain hose is about 18 long and hangs directly below the fuel filter housing When fuel
207. hts on the Mopar fuel transfer pump retrofit kit 05175538AA with instruction sheet K6855481 The kit retrofits all 98 5 02 Turbo Diesels These trucks were equipped with a Carter electric fuel transfer pump The kit includes all parts necessary to convert to a tank module mounted pump very similar to the design on 05 up Turbo Diesels Major items include a new fuel tank module electrical harness fasteners and fuel connection hardware and supplies A similar kit is also available for the 03 04 5 Turbo Diesels that currently use a fuel transfer pump mounted on the rear of the fuel filter housing e It s best to order by VIN because slightly different modules fit different size fuel tanks which can vary about 1 2 gallons on some models e Reason for retrofit As the readers are aware the infamous electric transfer lift pump design has been problematic and unreliable at best The controversy concerns a transfer lift pump that must lift fuel Dodge only application much farther than on other ISB applications The Dodge application requires that fuel be pulled in excess of five feet Contrast this to a ISB equipped Freightliner FL50 truck with a saddle tank less than three feet from the pump inlet Additionally many VP44 injection pumps would likely have not suffered catastrophic failure had the transfer lift pump not failed or partially failed which starved the injection pump of fuel and fuel cooling lubrication Th
208. ibrated fuel sealing unit Repair and replace as necessary ENGINE TSB 09 10 95 6 2 95 09 04 95 4 14 95 09 06 94 4122 94 09 22 93 12 31 93 09 07 91 12 2 91 09 11 89 7 3 89 A Publication of the TURBO DIESEL REGISTER MODELS 94 95 BR 94 95 BR 94 BR 94 BR 91 92 AD SUBJECT DESCRIPTION Diagnosing oil consumption The concern is an operator report of greater than one quart per one thousand miles Variations in oil level are likely possible if the oil check is performed on a warm engine due to slow drain back from the inline fuel pump Discuss with customer and assure dipstick is updated to part number 4796874 The correct dipstick increases the safe zone to two quarts versus the early 94 vintage dipsticks with only a one quart safe zone Excessive oil drainage from oil draft breather tube The bulletin applies only to engines built prior to 12 1 94 It involves replacing the tappet cover with a new sealed version Cummins exhaust manifold gaskets Service gaskets and production gaskets can vary in thickness Do not intermix If an exhaust gasket requires replacement then replace all six Service manual revision for Cummins piston grading procedure The information only bulletin details the pistons to be used if engine rebuild is necessary Cylinder head bolt torque tightening procedure The information only bulletin describes the bolt tightening procedure
209. ical gauges go from 130 to over 180 Because of their complexity the mechanical gauge is not recommended Owners of the 00 02 trucks would need a 19 fuel pressure line to marry the fuel pressure sending capillary tube to the fuel system Step Two Whose Fuel Transfer Pump This is the 150 210 400 or 650 decision Starting at 150 Purchase a spare Cummins fuel transfer pump part number 3990082 Monitor the fuel pressure with your gauge and become familiar with how to change the pump at its location on the engine 115 116 Moving to 210 Purchase a spare Cummins fuel transfer pump Purchase a transfer pump relocation kit for 59 Vulcan Performance Geno s Garage and move the transfer pump to an easy to access location on the truck s frame rail The benefits of relocation the transfer pump is not subjected to continual engine vibration the transfer pump is closer to the fuel tank and operates more like a pusher pump Should the pump fail the pump is very easy to access Moving to 400 There are several vendors that sell performance type fuel transfer pumps If youve made changes to the engine that have pushed your horsepower to over 300 you ve likely already added one of these pumps TDR writer Joe Donnelly discussed the FASS system www dieselpp com in his Issue 54 column Other vendors Pure Flow Technologies www pureflowtechnologies com Glacier Diesel Power www glacierdieselpower com and Vulcan
210. ike the DRB III may erroneously display certain Diagnostic Trouble Codes DTC as P0000 As a result the scan tool may display Freeze Frame data incorrectly The PCM software must be updated to calibration level OICall4A TSBs Issued During 03 CATEGORY 2 FRONT SUSPENSION TSB MODELS SUBJECT DESCRIPTION 02 003 02 00 02 BR BE Toe in specification change 6 17 02 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 CATEGORY 3 REAR AXLE TSB MODELS SUBJECT DESCRIPTION 03 001 02 02 BR BE Front axle disconnect system 2 11 02 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 52070136A0O 52070137A0O 52070138AP and 52070139A0 The vehicles involved will retain Shift On the Fly SFO capability however with this change the front driveshaft will now turn continuously when the vehicle is being driven Due to the timing of this change this information is not re
211. ill condition is not damaging to the engine The Cummins part number is stamped on the dipstick The incorrect Cummins P N is 3944594 The problem is corrected with the installation of a revised dipstick 05014562AA Cummins 3935648 CATEGORY 11 EXHAUST TSB MODELS SUBJECT DESCRIPTION 11 08 98 94 98 BR Turbo Diesel wastegate actuator repair kit 9 25 98 A new kit has been released that will allow technicians to repair turbochargers with failed wastegate actuators CATEGORY 14 FUEL TSB MODELS SUBJECT DESCRIPTION 14 01 98 98 BR High pressure fuel line service Rev A This bulletin supersedes technical service bulletin 14 01 98 dated March 6 1998 This information 7 17 98 applies to the 5 9L Cummins electronically injected 24 valve diesel built prior to engine serial number ESN 56462592 Design revisions have been made to the injector connector tube and the new design can be re torqued multiple times without compromising the seal between the connector tube and high pressure fuel line The new part number for this connector tube is 05013856AA Cummins 3944833 14 02 98 98 BR Fuel filter requirements 3 27 98 With the introduction of the Cummins 24 valve electronically injected engine a new VP44 injection pump was also introduced The VP44 injection pump requires finer fuel filtration due to tighter tolerances within the pump Whenever a fuel filter is replaced make sure the replacement filter is part number 04883963AB
212. in Control Module PCM with new software calibration changes 98cal12 and 99cal14 18 07 99 98 99 BR Erroneous MIL illumination with DTC A8 P1763 governor pressure sensor volts too high 04 30 99 This information applies to vehicles equipped with a reseries automatic transmission built before December 18 1998 Some vehicles may exhibit a MIL illumination with DTC A8 P1763 GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH The vehicle operator may experience slower than normal accelerations because the transmission may temporarily enter third gear Limp In Mode The Limp In Mode may last until the vehicle owner cycles the ignition key The technician may not detect a problem with the automatic transmission during a diagnostic test 52 A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE Continued 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 98Cal
213. in both regular cab and Quad Cab configurations The regular cab can be purchased with a 60 inch cab to rear axle length or a 84 inch cab to axle The Quad Cab can only be purchased with a 60 inch cab to rear axle length 11 12 2007 Turbo Diesel What is New New headlight design New rear taillamps Mid year introduction 2007 5 of Cummins 6 7 liter engine in consumer pickup models 2500 and 3500 Mid year introduction of a Chrysler supplied 68RE six speed automatic transmission Mid year introduction February 2007 of commercial Chassis Cab models 4500 and 5500 Models Available Same as 2006 2500HD as standard cab quad cab short bed long bed 4x2 and 4x4 3500HD same as above The dual wheel 3500 is not offered with a short box The Mega Cab is available in the 2500 or 3500 single rear wheels or 3500 dual rear wheels It is only offered with a short cargo box Chassis Cab Models The Commercial Chassis Cab trucks are initially available as a 3500 series truck The 3500 series truck is available in single or dual rear wheels SRW DRW The truck is available in both regular cab and Quad Cab configurations The regular cab can be purchased with a 60 inch cab to rear axle length or a 84 inch cab to axle The Quad Cab can only be purchased with a 60 inch cab to rear axle length Engine Ratings For early 07 models 325 HP and 610 ft lbs for consumer pickup models 2500 and 3500 This is a carry over of the C
214. inates for alternator charging with DTC P2502 P2503 or P2509 01 06 07 This bulletin applies to vehicles equipped with a 5 9 liter engine sales code ETH built on or before November 29 2006 The customer may experience the illumination of the Check Gauges lamp on the instrument panel cluster Inspection of the gauges may reveal that the battery charging gauge may read in the 11 volt range rather than in the 14 volt range There may not be a Check Engine Malfunction Indicator Lamp MIL illumination Further diagnosis may reveal the following diagnostic trouble codes DTC s have been set P2502 Charging System Error Diesel P2503 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 07 DC Ram truck 3500 Cab and Chassis Excessive soot accumulation in exhaust PCM may not Rev B reprogram and other engine system enhancements 07 13 07 This bulletin applies to Ram truck 3500 Cab and Chassis vehicles equipped with 6 7 liter Cummins Turbo Diesel engine sales code ETJ This bulletin supersedes technical service bulletin 18 009 07 Rev A dated May 16 2007 The vehicle operator and or technician may experience one or more of the following conditions The technician may not be able to reprogram flash the PCM with new application software e After extens
215. increasingly controlled by computer electronics 2002 Turbo Diesel What is New Although the gas engine 1500 models received a whole new body and interior the Turbo Diesel 2500 and 3500 model trucks experienced minor trim changes for this model year Models Available 2500HD as standard cab quad cab short bed long bed 4x2 and 4x4 models 3500HD as standard cab quad cab long bed 4x2 and 4x4 models The 3500 cab chassis line is discontinued Engine Ratings 235 HP and 460 ft lbs torque for five speed manual and 47RE automatic transmissions 245 HP and 505 ft lbs torque HO engine for six speed manual transmission only Transmissions Five speed manual NV4500HD 5th overdrive Six speed manual NV5600HD 6th overdrive Four speed automatic 47RE 4th overdrive with locking converter Maximum Tow Ratings 2500 regular cab and quad cab 4x2 and 4x4 both manual transmissions and both axle ratios 20 000 GCWR 3500 regular cab and quad cab 4x2 and 4x4 both manual transmissions and both axle ratios 20 000 GCWR 2500 and 3500 regular cab and quad cab 4x2 and 4x4 with automatic transmissions are rated 3 54 axle 16 000 GCWR 4 10 18 000 GCWR Note Maximum permissible trailer weight will vary by model and options Highest trailer weight ratings is for a 3500 regular cab 4x2 six speed manual 4 10 axle 15 150 pounds Lowest trailer weight rating is for a 3500 quad cab 4x4 automatic 3 54 axle 9 000 pounds
216. ine 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 Amaximum blend of 5 biodiesel B5 is acceptable as long as the biodiesel mixture meets ASTM specification D 975 D 975 grade S 15 and ASTM D6751 A biodiesel fuel blend that is higher than 5 is not acceptable without additional fuel processing because these higher percentage biodiesel blends contain excess amounts of moisture which exceed the water stripping capability of the on engine final fuel filter Should a higher percentage bi
217. ing the flow of lubricating oil ATF to the transmission overdrive unit This condition should be a concern only in areas where very cold ambient temperatures of 20 C 5 F are experienced The revised software will not allow 4 gear overdrive to occur if ambient temperatures are less than 20 C 5 F The revised PCM software has been implemented to improve transmission reliability The customer should be informed that reduced fuel economy would be expected when overdrive is not in use The repair involves selectively erasing and reprogramming the Powertrain Control Module PCM with new software calibration level 01Cal14 CATEGORY 25 EMISSIONS TSB MODELS SUBJECT DESCRIPTION 25 001 01 01 BR BE Generic Scan Tool May Not Display Certain DTC s and Erroneous LDP Switch 1 19 01 This bulletin applies to vehicles with an RE automatic transmission built before January 12 2001 MDH 0112XxX A generic scan tool may not display certain Diagnostic Trouble Codes DTC when a Malfunction Indicator Lamp MIL illuminates The PCM software must be updated to calibration level OlCall4A 25 002 01 01 BR BE Scan Tool Erroneously Displays P000 For DTC s P1740 And P0461 1 19 01 This bulletin applies to vehicles with an RE automatic transmission built before January 31 2001 MDH 0131XX A Generic Scan Tool or an Enhanced Scan Tool like the DRB III may erroneously display certain Diagnostic Trouble Codes DTC as P0000 As a result
218. integrated into seats on all extended cab and quad cab trucks New interior with redesigned dash Dash is electronic on 98 5 models 2500 short box extended cab and quad cab model with diesel is available Passenger side airbag with disable switch is standard Next generation airbags Heated power mirrors Illuminated door lock and power window switches Optional security alarm system 24 valve electronic controlled injection diesel offered as a 98 5 model Revised fifth gear nut on five speed manual transmission Models Available 2500HD as standard cab extended cab quad cab short bed long bed cab chassis 4x2 and 4x4 3500 Same as above No short bed models available Engine Ratings 12 valve head mechanical injection pump 215 HP and 440 ft lbs for manual transmission except California 180 HP and 420 ft lbs for automatic transmission and California manual transmission California engines continue with EGR Note A 98 5 engine was introduced 1 1 98 to meet more stringent emissions standards It included electronic control of fuel injection and a 24 valve cylinder head Rated at 235HP and 460 ft lbs of torque for manual applications and 215 420 for automatic transmissions No rating difference for California as the 98 5 engine was 50 state certified without EGR Transmissions No changes from 1996 Five speed manual NV4500HD 5th overdrive Four speed automatic 47RE 4th overdrive with locking converter
219. io 800 pounds 4 10 axle 400 pounds Derate trailer weight for extended cab 3 54 ratio 800 4 10 ratio 400 pounds Cab Chassis models Available in regular cab only 2500 is 8 800 GVWR 56 C A cab rear to rear axle centerline dimension 3500 is 11 000 GVWR and available in 60 and 84 C A dimensions Comments Trailer tow ratings begin to get confusing Performance complaints stem from computer programming of new electronically controlled automatic transmission Exhaust Gas Recirculation added to California trucks 1 1 96 to meet CARB emissions standards Owners begin to find out how easy and inexpensive it is to turn up the power A Publication of the TURBO DIESEL REGISTER 1997 Turbo Diesel What is New Hydraulic power brake booster powered from power steering pump Increased weight capacity to 11 000 GVW on club cab 3500 models Remote keyless illuminated entry option New AM FM Cassette CD player option Leather interior group option Models Available 2500HD as standard cab extended cab long bed cab chassis 4x2 and 4x4 Combo of short box extended cab diesel not offered 3500 Same as above No short bed models available Engine Ratings Same as 1996 model year 215 HP and 440 ft lbs for manual transmission 180 HP and 420 ft lbs for automatic transmission California engines continue with EGR but are offered with 180 HP and 420 ft lbs of torque in both automatic and manual transmiss
220. ion trucks with the NV4500 gearbox was the mainshaft nut backing off and making fifth gear useless or gone altogether TSB 21 10 98 Rev A from 9 25 98 addresses this issue in 13 pages of detail The replacement nut has a set screw to lock it in place after you ve installed thread locker and torqued it to 350 ft lbs The Dodge fix didn t always work since the original nut was cheaply made Sometimes a new gear was needed due to internal gear spline wear or a new transmission output rear shaft was needed due to external spline wear Sometimes the Dodge revised nut didn t work but the similar appearing Standard Transmission and Gear nut did Welding the nut onto the shaft didn t work as it crystallized the surface steel on the shaft and it later broke at the weld point There was no Dodge recall on this problem An avoidance tactic on 12 valve engines is to downshift from 5th to 4th gear when at full throttle at a minimum of 1 800 RPM to avoid excessive torque and engine vibration that causes the nut to loosen And remember to use GL 4 lubricant as called for by New Venture Gear and your manual Ref 24 p 27 146 p 17 Glitch The headlights don t work anymore Fix A problem common to many versions this is usually caused by running too many trailer lights The parking circuit in your light switch was never designed to run 40 clearance lamps on the trailer and it failed in protest Replacing the light switch does not solve the p
221. ion 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 24 A Publication of the TURBO DIESEL REGISTER CATEGORY 6 CLUTCH Continued 06 01 90 A 89 91 AD with Transmission noise below 1400 rpm 12 31 90 manual transmission The bulletin describes a powertrain induced cyclic noise condition that appears to be transmission driveline related Especially noticeable in 4th and 5th gears the noise occurs below 1400 rpm during coast or light throttle The noise is not damaging or durability related The diagnosis involves a road test to pinpoint the rpm at which the noise occurs The revision involves a change of the flywheel CATEGORY 7 COOLING TSB MODELS SUBJECT DESCRIPTION 07 04 94 94 BR Service manual revision thermostat seals 4 8 94 Revised service manual pages showing t stat seal pictures 07 07 94 94 95 BR Engine slow to warm up in cold ambient temperatures 9 30 94 The bulletin describes an overcooling condition caused by the thermostat being stuck in a partial open position Gauge fluction is addressed and is considered normal with no action required Owners ar
222. ion applications Transmissions No changes from 1996 Five speed manual NV4500HD 5th overdrive Four speed automatic 47RE 4th overdrive with locking converter Maximum Tow Ratings 2500 manual 4x2 regular and extended cabs 20 000 GCWR 2500 automatic 4x2 regular and extended cab 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR 2500 manual and automatic 4x4 regular and club cabs 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR 3500 manual 4x2 regular and extended cabs 20 000 GCWR 3500 automatic 4x2 regular and extended cab 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR 3500 manual 4x4 regular and extended cabs 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR 3500 automatic 4x4 regular and extended cabs Regular cab same as above Extended cab 4 10 axle only 18 000 GCWR 3 54 ratio not available with extended cab automatic option Cab Chassis models Available in regular cab only 2500 is 8 800 GVWR 56 C A cab to axle dimension 3500 is 11 000 GVWR and available in 60 and 84 C A dimensions New options include rear helper spring and stabilizer bar group 9 24 section modulus frame snowplow prep group with some engine transmission combos Comments California trucks have exhaust gas recirculation and net horsepower is lower Last full year of the 12 valve engine production 1998 Turbo Diesel What is New Quad cab option featuring doors on each side of extended cab with no B pillar Front seat belts
223. ion n 1 A brief conclusion or judgment not substantiated by proof 2 An evaluation based on special knowledge The TDR offices are only 20 steps away from the accessory business of Geno s Garage The Geno s phone rings and the voice on the intercom asks for assistance Can someone help the customer on line one with a fuel pressure gauge question Should the Geno s staff offer an opinion based on Webster s first definition or Webster s second definition Future success in business dictates that definition 2 be used As I ve overheard the dialogue so many times the exchange goes something like this GG What year model truck do you own Customer It s a truck pick your year 98 5 to 02 with a 24 valve engine I ve heard opinions that need a fuel pressure gauge What do you think GG Yours is a 24 valve engine yes you need to monitor the fuel pressure We ve got gauges and accessories in stock that will make installing the gauge an easy project Customer Okay what do you suggest and how do install a gauge GG Do you want the long story or the short story Customer I ve got time GG Here goes The 24 valve engine s VP 44 fuel injection pump relies on fuel from the transfer pump to keep the VP 44 s internal parts lubricated and cool A bad fuel transfer pump and the transfer pump is known to be problematic means a loss of fuel pressure to the VP 44 and often leads to the demise of
224. is a squawk caused by the metering valve spring chattering when the brake is depressed The bulletin involves the installation of a revised metering valve 05 04 92 A 89 92 AD Premature brake wear on trucks with 12 brake drums 4 21 92 sales code BKH BKJ The bulletin involves replacement of the rear brake shoes lining with revised shoes 05 01 91 81 91 AD Rear wheel anti lock speed sensor connector repair procedure 1 28 91 If a red amber ANTILOCK warning light illuminates and a code 9 diagnostic code is found a possible cause is the connector for the RWAL speed sensor The bulletin describes the repair procedure and parts needed to correct the problem 05 05 91 90 91 AD Front disc brake noise from Bendix disc brakes 8 12 91 The bulletin applies to trucks with Bendix disc brakes 3 38 caliper pistons Noise can occur and the repair involves grinding a chamfer on both ends of the outboard brake pad 05 07 90 89 90 AD Rear wheel anti lock faults caused by water contamination 9 24 90 A possible cause for illumination of the BRAKE and ANTILOCK warning lamps could be water contamination of the 4 way connector at the hydraulic valve and or at the 50 way connector The bulletin describes the repair and parts necessary to add a service jumper harness to the existing harness TSB MODELS SUBJECT DESCRIPTION 06 01 94 89 93 AD with Transmission noise below 1400 rpm 8 12 94 manual transmiss
225. is drained it is difficult to catch because the drain hose is not easily accessible To correct this condition slipped a three foot length of 5 8 heater hose over the existing drain hose perfect inside to outside diameter interference fit Extend and tie wrap your longer drain hose to a convenient drain location e Purchase a one gallon plastic fuel container Keep it filled with quality diesel and use the fuel to pre fill your filter Do not store diesel fuel in metal zinc lined cans the diesel fuel reacts with the zinc and forms a goo that can clog a filter and damage a fuel injection pump The advisability of pre filling the filter was debated in Issue 43 on page 148 Caterpillar heavy equipment mechanic and TDR member Craig Hubachek maintains that this technique is a service no no as it puts unfiltered liquids fuel or oil on the filtered side of the filter The audience should use due caution if you use the pre fill technique Note that since the 98 5 model year with the truck s electric fuel lift pump and self venting fuel system the self priming nature of the fuel system make the pre fill unnecessary A Publication of the TURBO DIESEL REGISTER Let s Begin the Fuel Filter Change e First extend the drain hose e Position your newly added drain hose in a location that is easy to reach and easy to catch Open the drain valve and drain the fuel from the filter canister The drain handle is open Unlike the 00
226. ith the remote mounted aftermarket Prime Loc fuel filter have experienced cracking of the bolt which holds the adapter to the Cummins fuel filter mount boss This results in serious fuel leakage Either replace the standard bolt with a modified bolt or check frequently for fuel leakage The fuel filter element should be changed at every other oil change or every 12 000 miles Always prime the fuel filter before placing a new one on the engine Then follow the procedure for bleeding the remaining air from the fuel filter assembly prior to starting A Publication of the TURBO DIESEL REGISTER On all 12 valve engines with the P 7100 injection pump all 94 98 5 trucks a fuel return line runs from the engine side of the injection pump near the front of the pump to return unused fuel to the fuel tank Part of the line is rubber This rubber line hidden under the intake manifold is subject to heat deterioration and should be replaced approximately every 50 000 miles This problem has been well documented in the TDR Issue 19 page 26 has the best write up See the picture below Look closely for the problematic fuel return line All rubber fuel lines both supply and return should be checked periodically for integrity Some lines can leak fuel or admit air to the system or cause loss of prime and resultant hard starting Starting in 1994 the Cummins engine is equipped with a pre strainer fuel heater It is located low on the
227. itten to stress the importance of using the correct lubricant by giving you some of the technical reasons behind the lubricant s uniqueness LUBE OIL CONSIDERATIONS Many of you inquire about selecting the best for your truck We hear a lot of questions like How about Mobil 1 or the Castrol Syntec synthetic lubricants Good intentions but these oils are not blended to meet the requirements of a diesel The API American Petroleum Institute donut rating for both oils is CD Note the first letter C stands for Commercial or compression engine a diesel The D is the specification test the oil was tested at and was able to pass The D specification was developed in 1952 Up until the 07 5 6 7 liter engines the diesel specification was Cl 4 plus SM For 07 5 it changed to CJ Is the CJ specification better than Cl 4 Good question Up until the CJ introduction the lube oils were better as the specification evolved But our Issue 54 thru 58 magazines had a lengthy discussion on why CJ may not be better than Cl 4 for the pre 07 5 engines The oil also needs to pass the API S S stands for a service or spark gasoline engine category and current specification M The S classification is needed to address and prevent wear on the sliding camshaft tappets 14 142 MANUAL TRANSMISSION 1994 2003 Five Speed NV4500 Manual Transmission Reference your Owner s Manual and you ll note instructions to c
228. ive idling of the vehicle engine or if an intake air leak is present the vehicle operator may experience a MIL illumination and or an electronic vehicle information center EVIC message alert due to one or more of the following DTC s P1451 Diesel Particulate Filter System Performance P2463 Diesel Particulate filter Soot Accumulation P242F Diesel Particulate Filter Restriction Ash Accumulation e The vehicle operator may experience a MIL illumination due to one of the following DTC s P0101 Manifold Absolute Pressure Sensor Performance P0106 Boost Pressure Sensor Rationality P0191 Fuel Rail Pressure Sensor Circuit Performance e 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 86 A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE Continued 18 030 07 04 07 Engine off idle speed limit feature to protect turbocharger when vehicle is not moving 04 26 07 DR DH D1 DC 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 featur
229. ivetrain upgrades Issue 30 page 36 Premium diesel fuel and fuel additives Issue 36 page 24 Issue 30 page 12 Differential repair Issue 41 page 150 Issue 24 page 42 Antifreeze coolant change Issue 35 page 76 Moto Connoisseurism and the desire for something better Issue 38 page 68 Braking systems in plain English Issue 40 page 96 Banks land speed record and Bonneville coverage Issue 39 page 30 Trailer towing capacities and payload limits Issue 35 page 30 Air Fuel Power revisited Issue 41 page 22 Fuel quality and the gasoline in diesel article Issue 39 page 138 Automatic transmission upgrade Issue 36 page 46 The options and specifications for all of the different year model trucks Issue 34 page 74 NV4500 upgrade for a First Generation truck Issue 21 page 115 24 valve fuel pressure specifications Issue 32 page 38 24 valve valve adjustment procedure Issue 30 page 54 The above list makes me thankful for the many indexes that TDR member Clay Maxam has compiled for us It made the task of finding that article about valve adjustment easy My vote for the most memorable TDR articles Clay s indexes from Issue 41 37 33 29 25 21 and 17 Certainly have found these most useful pulled out my Issue 17 magazine Clay s index of magazines 1 16 and reminisced We have covered so many topics It was interesting to note your favorites and the listing made above m
230. k and leak fluid which could result in significant transmission damage Repair The transmission cooler line must be replaced on all involved vehicles In addition the engine mounted transmission cooler must be inspected and replaced if necessary CUSTOMER SATISFACTION NOTIFICATION NO C42 POWERTRAIN CONTROL MODULE CONNECTORS Date February 2004 Models 03 DR This notification applies only to trucks equipped with a 5 9 liter Cummins diesel engine sales code ETC or ETH and an automatic transmission sales code DGP or DG8 built through July 9 2003 The Powertrain Control Module PCM electrical connectors on about 70 000 of the above trucks may allow water to enter into the connectors Water and the resulting corrosion ina PCM connector can cause the speed control and or transmission overdrive function to become inoperative Repair The three electrical connectors on the PCM must be removed and inspected for corrosion If no corrosion is found the connectors must be sealed by installing rubber O rings onto the harness connectors If corrosion is found in the connector the transmission wiring harness and PCM must be replaced 97 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
231. ka jug It seems the spout diameter and lid threads are an exact fit to the oil fill opening and threads on your Cummins engine R J Stamper Member Scott Morneau adds that you can use the oil fill cap to test other potential bottles If the oil fill plug fits the cap of the bottle the bottle will likely fit in the oil fill port We are reminded that when changing engine oil the new filter should be primed with clean oil the filter will hold nearly a quart before installation on the engine This will cut the time the engine runs without oil pressure during its first start after the oil change Gus Hrncir Here s a free pre luber for your Cummins engine If your engine is not run for long periods or if you want to build oil pressure before starting it in cold weather or after an oil change disconnect the fuel shutoff solenoid wire and crank the engine for 15 seconds Reconnect the wires and crank it again to start it It s an almost free solution if you add a switch in the cab to make raising the hood unnecessary Excerpted from the Cummins Operations Manual the tip applies to all the 12 valve engines Here s the editor s all time favorite low cost service tip When removing the oil filter use a large heavy duty freezer bag After loosening the filter part way slide the zip loc freezer bag under and around the filter then spin the filter off and let it drop into the bag Zip up the bag No mess and it is then easy to remo
232. l activation in an attempt to enable the output in case the fault is intermittent The new TIPM software raises the TIPM circuit trigger point from 15 amps to 20 amps DTC s B166C and B1670 These DTC s indicate that a short circuit to battery voltage 12 volts exists in the wiring of one of the trailer electrical harness circuits A Publication of the TURBO DIESEL REGISTER 19 CATEGORY 8 08 026 06 06 DR DH D1 Rev A 10 25 06 08 044 06 07 DR 10 07 06 08 046 06 04 07 10 25 06 ELECTRICAL Continued 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
233. l dealers informing them that exhaust brakes are not approved for use with automatic transmission equipped trucks Issue 24 page 38 1999 Turbo Diesel What is New Deleted extended cab option in middle of model year Deleted side body trim from aft of rear wheels Electronic dash with all gauges run by computers Models Available 2500HD as standard cab extended cab quad cab short bed long bed cab chassis 4x2 and 4x4 3500 same as above except no short beds Engine Ratings Same as 98 5 model year 24 valve electronic injection control 235HP 460 ft lbs torque for manual transmissions 24 valve electronic injection control 215HP 420 ft lbs torque for automatic transmission Peak torque available from 1700 2700 RPM Transmissions Five speed manual NV4500HD_ 5th overdrive Four speed automatic 47RE 4th overdrive with locking converter Six speed manual NV5600 6th overdrive late availability and soon withdrawn from sale The ideal truck How about this 98 Quad Cab short box 4x4 A Publication of the TURBO DIESEL REGISTER Maximum Tow Ratings All configurations and axle ratios of manual transmission trucks 20 000 GCWR All configurations of automatic transmission trucks 3 54 axle 16 000 GCWR 4 10 axle 18 000 GCWR Note Maximum permissible trailer weight will vary by model and options For example 4x4 models are rated for lower maximum trailer weights than 4x2 models and extended quad ca
234. left side of the engine in the fuel line before the fuel transfer pump The strainer should be removed for inspection by unscrewing the bottom bowl of the unit The strainer should be cleaned checked at least every 40 000 miles or more often if contaminants clog your primary fuel filter This strainer is not shown in any Cummins parts books It has been the culprit for many complaints of low power as it performs its designed task of screening the fuel prior to the primary fuel filter 133 134 16 PROPELLER SHAFT AND U JOINTS Trucks with two piece driveshaft systems extended cab trucks can experience a vibration when towing a heavy load at engine peak torque RPM in lower gears The vibration lessens and then disappears as engine speed builds This vibration is caused by the center carrier bearing being moved sideways against the bearing carrier frame and is considered normal 18 VEHICLE PERFORMANCE All 4x4 trucks built after 1994 use engine vacuum to engage the front axle drive Periodically inspect the vacuum hoses going to the front axle for holes abrasions and splits A damaged vacuum hose will prevent the front axle from engaging when the 4x4 lever is shifted in the cab 19 STEERING Asteering clunk in two wheel drive trucks produced after 1993 can be traced to lube pushing out of the telescoping steering column parts into the rubber boot on the shaft Squeezing the boot to push lube back into the splined area is a
235. lesome part My answer to the question Do you have any suggestion s about transfer pump replacement for the 98 5 to 02 owners has not changed with the announcement of the Mopar retrofit kit 05175538AA First let s review the prpevious correspondence from Issue 48 Okay this is another of my favorite topics Many TDR members have added aftermarket fuel pumps to work in tandem with or in lieu of the existing factory pump The drawback to any aftermarket accessory is that the owner is now responsible for installation of the product special parts and tools to support the installation and parts necessary should the new and improved accessory fail Admittedly the original fuel transfer pump has been problematic However before would recommend going the aftermarket route would suggest the keep it simple stupid solution Purchase a spare Cummins transfer pump Yes the part number has been superseded numerous times the final kit number 3990082 a 4943048 pump and 4025182 harness The current price at a Cummins distributor is 180 Next read and copy and understand the previous article showing how to replace the fuel transfer pump By using the factory parts you ll not have to worry about special aftermarket parts to complete the repair that may not be available when the truck breaks down Additionally my suggestion for all 24 valve owners is the purchase and installation of a fuel pressure gauge
236. light coat of chassis grease on one surface and place the gasket on it The gasket will then stay in place and be lined up for the rest of the installation Robert Patton When checking the oil level in your automatic transmission it is important to follow the Owner s Manual directions that specify checking the level with the transmission in neutral not in park Does the transfer case shift lever in your 4x4 truck buzz and vibrate Remove the trim and cement a small piece of rubber inner tube to the shift gate in the 2H position Alternatively you can place a wire tie on the lever where it passes through the shift gate WL Mayo and Robert Patton In a standard oil change of the automatic transmission only about five quarts of the old fluid can be drained out To get a complete change for example when switching to synthetic fluid disconnect the transmission cooler line at the radiator cut and fit a piece of hose to the coupler end and place the other end in a five gallon container Put your truck in park with the brake on and start the engine ATF will flow into the container As soon as the flow begins to dwindle immediately shut off the engine Reattach the cooler line and refill the transmission with fresh ATF before restarting the engine It may take up to 11 quarts Scott Dalgleish 23 BODY Charles Shields wrote in to say he had a problem with dust entering his instrument cluster through the odometer reset button hole He i
237. ll cause the truck not to start or the starter won t disengage after the engine fires A heavy duty contact kit is available from Larry B 49 p 154 to fix the problem Glitch Gauges don t work Fix The cause is most often a poor ground between the dashboard and the body chassis and engine Run new ground straps from the dashboard frame to the body from the body to the frame and from the frame to the engine This can affect all diesel Rams A secondary cause on 99 to 02 trucks is a faulty connection between the dash display driver cable and the PCM Glitch Gauges do work but the fuel reading is inaccurate On 89 to 02 trucks the Dodge only fuel tank sending unit fails either by becoming stuck at a certain fuel level or by reading low level at all times Fix The only solution is to drop the fuel tank and replace the sender The barrel strainer the level sender attaches to may also develop a glitch where it doesn t move up and down with fuel level thus leading to erroneous level readings Replace the barrel strainer Ref 49 p 148 Glitch My clutch won t release Fix This may happen to any Dodge diesel If the clutch fails to release upon stopping the truck either the clutch master slave cylinder circuit has failed thus requiring replacement or the pilot bearing in the flywheel which captures the nose of the transmission input shaft has failed allowing the input shaft to be deflected sideways when th
238. lose causing a lack of air discharge out of 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 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 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 A Publication of the TURBO DIESEL REGISTER 95 RECALL NOTICES OUTER DASH SILENCER PAD AND HEAT SHIELD SAFETY RECALL 737 The outer dash silencer pad on the below listed ve
239. ls is reported during the warranty period Fix If your Third Generation truck is hard to start or offers limited output check the CP 3 high pressure fuel pump that feeds fuel at 23 000 PSI to the fuel manifold Failure of the high pressure fuel pump is cured by pump replacement You should also check the voltage at the electric in tank fuel pump There is no TSB on either of these at this time Glitch Excess truck washing due to fuel spills Fix Fuel can spill on the painted fender surface from fuel overflow during the tank filling process on some Third Generation trucks Drill a small hole in the plastic piece surrounding the fuel filler opening below the fill tube opening to allow any fuel overflow to drain out rather than run down the painted side of your truck G R Whale Jim Anderson TDR Writers 12 Valve Dowel Pin Common Sensical Solution Always on the lookout for a better way to accomplish a task the folks at TST products have developed a common sensical is that a word method to correct the dowel pin problem that many owners have seen with their 12 valve engines Before present their solution let s provide a brief history of the problem The dowel pin has been starting with production in 1983 and continues to be used on the Cummins B series engine as a locating and alignment point for the attachment of the front gear cover to the engine block The problem that has been encountered by owners is predominately with
240. lting in hard crystalline deposits in the injector system Worried about being in the middle of nowhere and running out of fuel Cummins reminds us that the 12 valve B 5 9 engine will run on fuels besides 1 and 2 diesel and blends thereof Alternate fuels include 1 K and 2 K kerosene Jet A Jet A 1 JP 5 and JP 8 jet fuels Fuels not approved by Cummins are Jet B JP 4 and gasoline Cummins stipulates that alternative fuels must be used only in an emergency and that the engine runs best and most efficiently on 2 diesel fuel On 94 through 98 12 valve Cummins engines there is a fuel pre filter neater that most mechanics don t know about It is located between the fuel tank and the fuel transfer pump low on the engine left side near the rear The bottom bowl screws off and the plastic strainer screen should be cleaned periodically Don t forget to properly reseat the gasket before reinstalling the filter bowl Robert Patton If you damage or lose the fuel pre strainer gasket during servicing you have two alternatives Purchase a kit from Dodge for 27 00 which contains the gasket or go to an industrial rubber supply house and purchase a 2 3 4 x 3 x 1 8 rubber quad ring for less than 2 00 A perfect fit John Murry Acard is available from Flying J truck stops which entitles you to a one cent per gallon fuel discount minimum 20 gallon purchase The card is free and application blanks are available at all Flying
241. lves the replacement of the transmission valve body upper housing separator plate 21 12 00 00 01 BR Tapping knocking sound during idle 09 15 00 This bulletin applies to vehicles built before May 10 2000 equipped with an automatic transmission A tapping knocking sound may be heard or felt in the driver side floor pan area during idle conditions With the engine running at an idle listen for knocking sound coming form the driver side floor pan area If a tapping knocking sound can be heard replace the shift linkage with revised parts CATEGORY 23 BODY TSB MODELS SUBJECT DESCRIPTION 23 03 00 00 BR Vehicle Identification Number VIN Plate Relocated 02 04 00 The VIN plate on the subject model vehicles has been relocated from the instrument panel to the cowl bar Due to the relocation of the VIN plate the windshield frit the frit is the black out band at the bottom of the windshield required a change so that the VIN plate could be seen through the windshield The view of the VIN plate may be blocked if a 1999 or earlier windshield is installed on the vehicle Do not install or have class suppliers install 1999 or earlier windshields on 2000 model year subject model vehicles Likewise do not install or have glass suppliers install 2000 or later windshields on earlier models 23 19 00 94 01 BR Instrument panel creak 05 05 00 A creak or squeak may be present near the left and or right side s of the instrument pan
242. ly on site staff amounts to 25 50 people and if you put each in a car and spread them out on the big oval track there d still be a quarter of a mile of space between the cars The reptiles outnumber humans exponentially and they don t drive does that tell you anything So things go wrong with vehicles And without debating what might cause the TDR readership to be so adept at it or Dodge for the lack of satisfactory proving the readers do find many things that go wrong And then they figure out how to fix them When the first Dodge Cummins arrived in 1989 it had more than a few things going for it Apart from the engine and transmission not too much of it was new heck a lot of it could be traced to the early 1970s So again in theory the only new problems would be limited to the engine or some part of the driveline wiring or cooling system attached to it So let s begin our discussion with problems that can be associated with Dodge Cummins pickups in First Second and Third Generation order and randomly chosen by TDR writers Whale and Anderson Some are more infamous than others as it is with customers A Publication of the TURBO DIESEL REGISTER ACROSS THE BOARD Glitch My steering s sloppy or the tires are cupping Fix This one can oft be traced beyond pilot error although we re certainly not ruling that out It tends to be more of an issue on 4WD trucks and newer models have fewer pro
243. ly to a damp cloth and wipe back and forth across the affected area applying moderate pressure Rinse off the residue when finished CLEAN YOUR RIDE An easy to make bug scrubber that won t scratch paint can be made by wadding several pairs of old panty hose together and using it as a wet sponge This also works to remove tar from chrome trim Tired of getting spray tire dressing all over your newly cleaned wheels Make a cardboard template to hold over the rims and spray away It is likely you already have a great tar remover in your toolbox Spray WD 40 on the tar let it sit then wipe the tar off It won t hurt the paint either If you want the interior of your ride to always smell fresh and clean lay a bar of Irish Spring soap under the seat If you want a different scent a sheet of fabric softener works too Your truck is washed and it is time to dry it Before you break out the towels chamois let s play a litlle bit longer and put the water to work drying the vehicle Say what Follow the procedure Remove the spray nozzle from the hose Starting at the roof let the steady stream of water collect the drops and flow them off the surface Move to the windshield hood windows doors cargo box tailgate The A Publication of the TURBO DIESEL REGISTER stream of water does a great job of drying your truck Finish off the job with your towel CLEAN YOURSELF A good way to clean your hands after a dirty job is to use
244. match mounting process to improve ride characteristics Spare tire winch operation The bulletin is an information only bulletin reminding not to use power tools to drive the spare tire winch Wheel runout measurement code WDC wheels procedures The bulletin gives the allowable remount and informs the dealer that the tire must be dismounted to correctly measure radial and lateral runout Match mounting during wheel service The information only bulletin helps dealers match mount wheels and tires Premature rust on chrome wheels Wheels manufactured after 1 1 94 have an improved chrome plating process Wheels prior to 1 1 94 may show signs of premature rust Replacement of the wheels is described Tire and wheel runout A quick reference chart is provided for dealer diagnosing Wheel vibration on 350 Series trucks with flange type lug 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 SUBJECT DESCRIPTION Rattle due to seat belt latch plate bumping trim The symptom is a noise due to the seat belt latch bumping against the trim when the belt is not in use The repair involves the addition of a sound deadener pad to the trim panel Cracked sunvisor support bracket retainer The bulletin involves the replacement of the visor bracket with a revised bracket Door operation not smooth or feels loose Visually inspect th
245. ms the majority of TDR owners take initiative to solve correct anticipate prepare for a future situation Thats what the TDR is all about And thanks to the support from Chrysler and Cummins we are equipped with answers and solutions rather than wonderment and isolation that would exist without a support group With the introduction out of the way resourced three important TDR articles Favorite Fumbles Fabulous Fixes looks at problems that we ve seen in the many years of the TDR magazine and web site 12 Valve Dowel Pin Solution gives a discussion and solution to the problem that can happen to a 89 98 12 valve engine Fuel Transfer Pumps Revisited talks about the low pressure fuel system for all year model trucks and then gives specific repair techniques for the vintage year truck you may own This is a must read for anyone with a 98 5 02 model year Turbo Diesel We hope you find Most Common Problems to be helpful in your evaluation of the Dodge Cummins Turbo Diesel pickup Favorite Fumbles Fabulous Fixes G R Whale and Jim Anderson Everyone knows the automakers have proving grounds where rather obviously part of the process is to prove things work In theory any part the customer can break can be broken under controlled circumstances at the proving grounds However customers routinely outnumber proving ground personnel At some western desert testing centers the typical dai
246. n 1 1 2000 Dodge introduced their trucks as 2001 models Coinciding with the 2001 pickups Dodge introduced the 2001 PT Cruiser For corporate average fuel economy CAFE criteria the PT Cruiser is classified as a truck We speculate the long model run of 2001 truck goes hand in hand with the higher mileage PT Cruiser thus giving Dodge an edge in the CAFE numbers The six speed manual transmission remained on back order all year due to high demand Phil Putnam Examples of 94 02 Second Generation trucks TDR Member Archives also 2001 5 models What is New New sport and off road badges Added child seat top tether anchors on quad cab rear seat Four wheel disc brakes are standard with vented rotors in rear integral drum parking brake as a 2001 5 model Four wheel ABS standard with new dynamic rear proportioning braking system as a 2001 5 model Servoless speed control for manual transmission diesels Forged aluminum wheel option on 2500 trucks One touch drivers side power window down feature on SLT and packages New engine ratings of 235 HP 460 ft lbs for both five speed and automatic transmissions New optional engine rating of 245HP 505 ft lbs for the six speed transmission Models Available 2500HD as standard cab quad cab short bed long bed cab chassis 4x2 and 4x4 3500 same as above except no short beds Engine Ratings 235 HP 460 ft lbs torque for five speed manual and automatic
247. n 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 91 93 AD Air conditioner compressor noise 11 19 93 94 BR A growling noise may be heard with the compressor running Diagnose the condition as outlined and perform the repair procedure if necessary The repair involves installing a revised compressor valve plate assembly CATEGORY 26 MISCELLANEOUS TSB MODELS SUBJECT DESCRIPTION 26 04 94 All Diagnostic procedure manuals 10 28 94 The bulletin gives a current list of available diagnostic procedure manuals These manuals provide system information step by step trouble shooting procedures diagnostic and driveability tests along with
248. n is present perform the repair procedure which involves replacing the reverse synchronizer 21 010 06 All Automatic transmission fluid usage ATF 4 Type MS9602 4 14 06 This bulletin supersedes technical service bulletin 21 004 04 dated March 16 2004 ATF 4 type 9602 is being used as factory fill for Chrysler Group automatic transmissions ATF 4 is recommended for all vehicles equipped with Chrysler Group automatic transmissions except for those noted AW 4 transmissions Sprinter transmissions Crossfire transmissions MK PM vehicles equipped with Continuously Variable Transmission CVT ATF 4 is backward compatible with ATF 3 ATF 2 and ATF Additionally ATF 4 can be used to top off vehicles that used ATF 3 ATF 2 or ATF Benefits e Better anti wear properties e Improved rust corrosion prevention e Controls oxidation Eliminates deposits e Controls friction e Retains anti foaming properties 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 A Publication of the TURBO DIESEL REGISTER 89 CATEGORY 21 TRANSMISSION Continued 21 003 07 Automatic transmission diagnostic tear down procedu
249. n often determine if a lift pump or overflow valve problem exists by doing the following test Let s assume we see a 12psi reading on our fuel pressure gauge With the engine idling and a pressure gauge attached slowly squeeze the rubber return line this infamous rubber fuel return line is often The Bosch P7100 over flow valve A Publication of the TURBO DIESEL REGISTER problematic but more on that subject in a minute that runs behind the fuel filter If the pressure gauge starts to rise it means that the lift pump is making good pressure and that the overflow valve may be opening too soon An overflow valve that opens at too low of a pressure will result in poor performance Too much fuel will return to the fuel tank which robs the injection pump of fuel pressure that is necessary for proper operation If the line pinch test makes little or no difference on the fuel pressure gauge it would suggest that the lift pump is weak Adrain manifold is available for excess fuel not injected by the six fuel injectors The return path is sequential at each injector and returned to the fuel filter inlet Usually these will leak fuel noticeably if a problem occurs allowing the owner to quickly pinpoint the leak 4 3 ND i a r t 22 1 Ge amdige A 1 Notice the return line parts diagram illustration for 1998 12 valve Part number 8 rubber fuel return line is about three times as long on the earlier 12 valve
250. n the A pillar and the dash panel plenum lower rubbing together This bulletin describes the repair procedure which involves loosening the instrument panel and providing additional clearance between the A pillar inner panel and dash panel 23 18 99 98 99 BR Bezel comes loose from seat belt retractor cover 05 21 99 This bulletin applies to club quad cab vehicles The seat belt retractor cover bezel comes loose due to a cracked seat belt retractor cover The crack may occur at the bottom of the opening where the seat belt bezel snaps into the cover This bulletin describes the installation of a new seat belt retractor cover 23 22 99 94 00 BR Rattle in door area 07 02 99 This bulletin supersedes technical service bulletin 23 46 96 dated August 2 1996 Customers may complain of one or more of the following symptoms rattle heard in the door area door window shakes when closing door lower window channel bolt has pulled through the door sheet metal door sheet metal is cracking around the lower window channel bolt This bulletin involves removing the window channel from the door and installing a revised window channel 23 28 99 98 99 BR Power seat track vertical adjustment stuck in a full upward or full downward position 08 13 99 This bulletin applies to club or quad cab vehicles built before March 1 1999 The repair condition is that the front and or rear power seat track vertical adjuster motors are stuck in a full u
251. nce 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 06 08 Repair of etched paint 10 30 07 DR D1 DC DH 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 94 A Publication of the TURBO DIESEL REGISTER CATEGORY 24 HEATING amp A C TSB 24 003 03 5 23 03 24 004 03 6 13 03 24 006 06 8 9 06 24 021 05 12 16 05 MODELS SUBJECT DESCRIPTION 90 04 A C system additives All Chrysler group The use of A C system sealers may result in damage to A C refrigerant recovery evacuation products 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 03 DR Defrost door inoperative The defrost door may break at the pivot shaft causing inadequate travel The system may not completely c
252. nd terminal at the generator 06 23 00 While service is being performed to the engine it may be possible for a momentary electrical short to occur The electrical short may be caused when a metallic object such as a wrench or oil filter comes in contact with the B end terminal of the generator wire harness The B end terminal is bolted to the generator B stud output terminal The B stud on the generator is protected by a plastic surround Part of the wire harness end terminal may extend beyond the protective plastic surround for the B output terminal This bulletin applies to vehicles equipped with a 5 9L 24V diesel engine built before engine serial number 56681800 with a date of manufacture of January 29 2000 The repair procedure involves the installation of a protective rubber boot part number 04487042 over the B terminal 08 26 00 00 01 BR Central timer module electrically locks up 09 29 00 This bulletin applies to vehicles equipped with remote keyless entry sales code GXR In addition this bulletin applies to vehicles built on or before the following build dates Ram trucks built at the St Louis North Assembly Plant on or before August 21 2000 Ram trucks built at the Saltillo Truck Assembly Plant on or before August 31 2000 Ram trucks built at the Lago Alberto Truck Assembly Plant on or before September 6 2000 The repair involves replacing the Central Timer Module CTM with a revised part CATEGORY 9
253. nd the corrective action Should you need the entire text you should consult your dealer or use the www techauthority com web site to purchase the bulletin s pertaining to your truck One final note As mentioned the TSBs that we ve researched cover those issued from 2003 to date 8 2008 For clarity we have printed in bold the TSB number and the models of trucks to which the TSB applies The bold print will help you distinguish the old lisitngs from the newer ones CATEGORY 2 In an effort to consolidate the TSBs for the magazine we re going to use the same index system categories as DaimlerChrysler Below are the index categories 2 Front Suspension 14 Fuel 3 Axle Driveline 16 Propeller Shafts and U Joints 5 Brakes 18 Vehicle Performance 6 Clutch 19 Steering 7 Cooling 21 Transmission 8 Electrical 22 Wheels amp Tires 9 Engine 23 Body 11 Exhaust 24 Air Conditioning 13 Frame amp Bumpers 26 Miscellaneous A note concerning the TSBs and their use The bulletins are intended to provide dealers with the latest repair information Often the TSB is specific to the VIN VIN data on the Chrysler service network helps the dealer in his service efforts ATSB is not an implied warranty 2008 TSBs With the new service at www techauthority com we ve gathered information on Dodge Technical Service Bulletins that have been released thus far in 2008 These 2008 TSBs are incorporated into our summary listing FRONT SUSPENSION
254. ne Or the customer may complain of a hard or no start condition while the engine is at normal operating temperatures when using any type of good quality diesel fuel The poor driveability condition may occur only when either straight 1 diesel fuel is used or when other special cold climate winter blend fuels are in use The no start or long engine crank condition may occur when attempting to restart the engine while the temperature of the engine is till close to its normal operating temperature This hard hot restart condition may be experienced in all ambient climates but may be more of a concern in warmer ambient climates The repair involves selectively erasing and reprogramming the Cummins CM551 Engine Control Module ECM with new software 18 024 00 01 BR Low engine power when the automatic transmission is in overdrive 12 21 00 This bulletin applies to vehicles equipped with a 24 valve diesel engine and automatic transmission built between engine serial numbers 56666444 to 56798357 with a date of manufacture of December 15 1999 to November 15 2000 This information is available on the engine data plate which is located on the left side of the engine affixed to the side of the timing gear housing 58 A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE Continued The customer may complain of low engine power and or poor performance This engine condition may occur while the automatic transmission is bei
255. ne or moaning type noise from a cold transmission when reverse is selected 04 30 99 Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected This noise has been described as a buzz whining or moaning like noise The noise is most noticeable when transmission fluid temperature is below 100 degrees F 38C The condition is caused by a resonance of the transmission regulator valve system The repair involves replacing the transmission regulator valve 21 14 99 00 BR 47RE transmission harsh or early shifts 11 05 99 This information applies to vehicles equipped with a 5 9L 24V diesel engine and 47RE automatic transmission built before engine serial number 56624822 with a date of manufacture of August 54 A Publication of the TURBO DIESEL REGISTER CATEGORY 21 TRANSMISSION 28 1999 This information is available on the engine data plate which is located on the left side of the engine affixed to the gear housing Some early built 2000 model year Ram Trucks may experience a harsh 3 4 shift This condition may occur during any throttle position situation when transmission sump temperatures are 60 degrees F 15C or higher The harsh 3 4 shift may be more pronounced during heavy vehicle loading e g trailer towing Some 2000 M Y vehicles may also experience an early 1 2 or 2 3 shift condition during wide open throttle WOT situations This condition may have an impact on vehicle performance ac
256. nformed you will become as a buyer Now is also the time to make a call to your automobile insurance agent for a rate quote to make sure there are no after the purchase unpleasant surprises in this part of truck ownership If you plan to get a loan for the vehicle now is also a good time to shop around for the best interest rate and payment plans and to get approval for the loan It is as important to shop for the cost of money as it is to negotiate a good price for the truck After you have done your research then it is finally time to go looking for just the right truck You now have a pretty good idea of what you want what you might have to pay and how you re going to pay for it My advice is to buy the latest model truck with the lowest mileage that you can afford The newer the truck the lower the maintenance and repair costs are likely to be over time Look for a well maintained cream puff They re out there but it is up to you to find them Inspection Time In looking at a used vehicle don t be dazzled by surface shine Look behind the shine to uncover a vehicle s true condition Look at the truck s overall cleanliness There is A Publication of the TURBO DIESEL REGISTER a difference in appearance between a good cleanup job and continuous regular cleaning over the truck s life to the present Look at the interior for worn carpets and upholstery The editor s favorite place to check for attention to de
257. ng 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 02 BR BE Locking radio antenna connector 8 3 01 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 02 BR BE Safety systems Vehicle modifications repair 9 21 01 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 94 01 BR BE Airbag on off switches 11 23 01 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
258. ng operated in its overdrive gear This condition may be further aggravated if the customer is using the vehicle for towing purposes The Engine Control Module ECM software on a 2001 Ram Truck equipped with a 24 valve diesel engine is designed to torque manage the power output of the engine This is done to protect the automatic transmission components The revised software calibration restores the power output and improves the vehicle performance in overdrive Note If TSB 18 015 00 Rev A has previously been performed too the vehicle in question then the ECM software has already been revised with the correct calibration to address the above condition The ECM will not require reprogramming The repair procedure involves selectively erasing and reprogramming the Cummins CM551 Engine Control Module ECM with new software calibration versions 56113 59T6 There is no change to the JTEC PCM software CATEGORY 19 STEERING TSB MODELS SUBJECT DESCRIPTION 19 04 00 94 00 BR Squeaking creaking sound in steering column while turning 06 09 00 This bulletin applies to vehicles equipped with non tilt steering columns A squeaking creaking sound may be heard coming from the area of the steering wheel while turning The sound is associated with rotation fo the steering wheel or may be heard while going over bumps in the road The repair involves installing new lock housing attaching screws CATEGORY 21 TRANSMISSION TSB MODELS
259. nge every 30 50 thousand miles depending on load Use 75W 90 GL 5 rated synthetic oil for normal light to medium load duty cycle Tires Weekly check for proper air pressure with tires at ambient temperature Follow the Owner s Manual recommendations for increasing pressure as load increases Front 45 55 Ibs Rear 40 80 Ibs Cold Starting Turn on key and when wait to start light goes out start the engine You may need to apply light throttle up to 1 000 RPM to keep the engine running if it is very cold Allow two or three minutes of idling time for oil to circulate in the engine before driving away Use light throttle until engine has fully warmed up Washing and waxing New paint is soft for the first 30 to 60 days after spraying and should cure up to three months before gaining full strength Wash your new truck with clean water on a cool paint surface for the first 30 days Use a soft cloth with a nap surface If the truck is very dirty use a mild car wash soap diluted in water and applied with a soft cloth Do not wax your truck for 30 days then use a cleaner wax which is suitable for clear coated finishes In this case logic prevails if 3 is good then 4 is better A Publication of the TURBO DIESEL REGISTER Mopar Cummins Fleetguard Part Number Reference Notes This table Includes part number supercessions as of 11 05 Part numbers at the top are Mopar middle are Cummins bottom are Fleetguard For
260. noise when the brakes are depressed The repair involves installing a revised back up plate into the brake combination valve 05 02 96 A 94 97 BR Accelerated brake lining wear front versus rear 11 15 96 2500 8800 GVW The bulletin supersedes TSB 05 02 96 dated 2 23 96 The bulletin adds the 3500 series truck sales code and 3500 and incorporates the use of revised brake linings The bulletin discusses wear conditions The built before 8 5 96 repair procedure involves replacing possibly the front brake linings rear brake linings or rear wheel cylinders depending on truck model and vehicle sales code 05 08 96 94 96 BR Brake pedal rattle 9 13 96 If a rattle is heard coming from the brake pedal area and is eliminated when pressure is applied to the side of the brake pedal a repair procedure involving a wave washer is outlined 05 09 96 All Brake noise 10 4 96 The information only bulletin describes the normal noises that may occur with a properly operating system ABS self check trace squeak grinding groaning etc noises are discussed 05 10 96 94 97 BR Chassis dynamics diagnosis 12 13 96 The bulletin discusses conditions where by the vehicle may move to the right or left when not controlled by the driver Several causes are cited aftermarket wheels road crown cross winds incorrect tire pressures worn wheel bearings etc Diagnosis involves testing the vehicle to determine if the drift is brake relate
261. 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 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 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 98 99 BR Radio interference to from two way radio receivers This bulletin addresses the complaint
262. ns 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 06 07 DR DH D1 Cracked windshield 10 21 06 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 06 07 DR DH D1 Water leak due to small void in backlite sealer 3 24 07 1500 2500 3500 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 A Publication of the TURBO DIESEL REGISTER 93 CATEGORY 23 BODY Continued 23 011 07 06 07 DR DH D1 Glass keeper loose on back power sliding
263. nsor plug Cycle the key twice just enough to bump the starter but do not turn the engine over This will cycle the fuel transfer pump in the fuel tank to refill the canister A Publication of the TURBO DIESEL REGISTER Start the engine and test for leaks Record the date and mileage in your truck maintenance record book If your truck runs and doesn t leak fuel you did good HBarlow And the editor thought to himself Why didn t I discover the 1 2 drive indentation on the bottom of the canister As you inspect the canister you ll notice that is an off only type indentation Thanks Harvey for the tip THE SEARCH FOR A 6 7 LITER FUEL FILTER ONLY Short answer You cannot purchase a fuel filter only The replacement kit is sold through Mopar 05183410AA Fleetguard FS43252 and Cummins 4936025 as a filter gasket O ring and plastic cartridge assembly Yes you get the plastic cartridge whether you need it or not The plastic cartridge is reusable right Long Answer To no avail the Geno s Garage staff tried for 18 months to purchase the required gasket O ring and filter from Fleetguard Fleetguard makes and packages the filter kit for Mopar I ve seen the notes from the e mail and the telephone conversations and the words dogged determination describe their pursuit of the lower cost filter only It is not to say that the Fleetguard FS43252 is outrageously expensive At less than 30 it is fai
264. nstalled a small O ring on the button shaft and now keeps a clean instrument cluster If your shoulder seat belt buckle rattles against interior trim while driving install a small piece of velcro on the back of the seat belt buckle trim where the buckle hits the trim With the velcro the buckle will stay in place Robert Patton To remove bugs from the grille area fill a spray bottle with one part diesel fuel one part water and a small amount of detergent Shake well and apply let it sit then hose it off Tom Clayton Four wheel drive 2500 series Dodge trucks come with plastic rear wheel well liners as standard while two wheel drive trucks do not The four wheel drive liners can be used on two wheel drive trucks with no modifications They are available through Dodge parts for about 60 00 per set The liners make cleaning easier and prevent mud and salt buildup in the fenderwells Do your outside rearview mirrors jiggle when going down the road For trucks equipped with an aftermarket wind deflector bugshield start your troubleshooting by removing it The same advice applies if your radio antenna whips about violently 24 AIR CONDITIONING Spray a disinfectant such as Lysol into the A C vents occasionally to kill mold and odors 26 MISCELLANEOUS Here are several cleaning tips After washing your truck give it a final rinse using water from the hose without the nozzle on it The solid stream results in fewer water
265. nt brake caliper anti rattle clip retainer service procedures 06 09 00 This bulletin applies to vehicles built before June 26 2000 Vehicles built between April 19 2000 and June 26 2000 were built with a front brake caliper anti rattle clip retainer This Technical Service Bulletin provides the installation procedures for the retainer CATEGORY 8 ELECTRICAL TSB MODELS SUBJECT DESCRIPTION 08 05 00 99 BR Intermittent operation of the instrument cluster 04 21 00 The needle of the instrument cluster gauges may intermittently drop to zero and or the telltale lamps such as the AIRBAG warning lamp may intermittently come on The bulletin involves replacing the instrument cluster wire harness connector and associated wire terminals 08 08 00 99 00 BR Inoperative or intermittent remote keyless entry RKE transmitter 03 17 00 The problem described is an inoperative RKE transmitter This condition may be intermittent and will have similar symptoms to a dead transmitter battery This bulletin discusses replacing and reprogramming the RKE transmitter 08 11 00 94 00 BR Recordable compact discs used in automotive CD players 03 24 00 Some recordable compact disc media such as CD R and CD RW may not comply with the standard 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
266. nt 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 A Publication of the TURBO DIESEL REGISTER n CATEGORY 14 FUEL TSB MODELS SUBJECT DESCRIPTION 14 001 02 02 BR BE Fuel cap difficult to remove Rev A This bulletin involves installing a revised fuel cap 10 7 02 14 002 02 98 02 BE BR Tampering with VP44 fuel pump on Cummins diesel engine Rev A This bulletin supersedes technical service bulletin 14 002 02 dated July 1 2002 A number of 7 22 02 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 PCode Description 124 P 0234 Turbo boost limit exceeded 146 P0217 Decreased engine performance due to engine overheat condition 361 P 0254 Fuel injection pump fuel valve current too high 363 P 0251 Fuel injection pump mechanical failure fuel valve feedback circuit 364 P1689 No communication between ECM and injector pump module 375 P0602 ECM fuel calibration error The diagrams show the area where performance enhancing equipm
267. nt parts The TST shop guys have this project down to a two hour science Lots of removals are necessary but the repair is simple in scope 1 Drain and remove the coolant overflow tank 2 Drain and remove or push to the side the windshield washer tank 3 Remove 10mm bolts 4 and clips that hold the fan shroud in place The fan shroud will later be removed with the fan in step 7 4 Remove engine accessory drive belt using your 3 8 ratchet in the belt tensioner access socket 5 Cut a piece of cardboard big enough to cover the engine side of the radiator Tape the cardboard into place 6 Locate the 10mm bolts 4 for the fan support bracket Remove the three 1 2 3 easy to access bolts The last bolt 4 can only be removed with an open end wrench Support the fan assembly with one hand and loosen the bolt with the other making sure not to damage the radiator fins 7 CAREFULLY work the fan and the fan shroud out together This takes time so go slow Working with a friend helps Make sure not to DAMAGE the radiator cooling fins or any hoses that may be in the way 105 106 8 9 10 11 12 14 Remove the engine oil fill tube located at the front upper side of the gear case To do this remove the one 16mm bolt from the bracket to the cylinder head and loosen the 8mm bolt that clamps the bracket to the oil fill tube Now rotate the bracket out of the way and with the use of a large
268. ntial oil change Jack up each side of the rear axle for five minutes each to ensure that oil reaches the axle bearings then lower the truck to a level floor and check the fluid level Add additional fluid as necessary to complete the fill On some trucks with heavy duty suspension and overload springs suspension noise from the overload springs slapping the frame stop can be annoying Slip and tighten a plumber s pipe connector over the end of the frame stop A plumber s pipe connector is a 3 diameter rubber tube about 4 long and about 3 8 thick with a stainless steel hose clamp on each end It is available at plumbing supply shops or stores such as Home Depot for about 4 00 each Frank Howatt Another method to cure overload spring slap is to cut and fit a piece of old tire carcass to the overload spring end using one clamp to attach it at the axle end only The cost is less than a dollar per side John Holmes 7 COOLING 1989 and 90 Turbo Diesels were not equipped with an air to air intercooler These trucks tend to run hot in the summer on long pulls Member Tom Clayton used a section of 4 aluminum dryer vent hose to direct cool air from the front of the truck onto the turbocharger area He also installed a revised Cummins thermostat P N 3802273 which further improved engine cooling To protect the cooling system from bugs and debris insert an old aluminum framed window screen behind the grille and ahead of the ra
269. occur The correction is to install anti friction tape to the inside edge of the doors 94 BR Pickup box floor rattle The bulletin involves applying sealer to the pickup box floor at the crossmember 94 BR 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 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 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 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 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 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 r
270. odiesel fuel be used an auxiliary water stripping filter will be required A maximum blend of 20 biodiesel B20 can be used by government military and commercial fleets who equip their vehicle s with an optional water separator and adhere to the guidelines in the Department of Defense specification A A 59693 Fuel conditioners additives are not recommended and should not be required if you buy good quality fuel and follow cold weather advice supplied in the Owner s Manual A Publication of the TURBO DIESEL REGISTER 83 CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS SUBJECT DESCRIPTION 18 015 03 03 DR Powertrain control module PCM shift quality improvements 4 4 03 This 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 03 DR No throttle response lack of power while towing and diagnostic trouble codes P2638 P0700 7 4 03 This bulletin applies to vehicles equipped with a Cummins diesel engine sales code ETC or ETH built on or before July 25 2003 The vehicle may exhibit e No throttle response if the engine is started with the Accelerator Pedal Position
271. 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 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 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 amp 00Cal13A A Publication of the TURBO DIESEL REGISTER 51 CATEGORY 8 ELECTRICAL Continued 08 42 99 98 99 BR The fuel gauge reads full for an excessive period of time 12 17 99 This bulletin applies to vehicles equipped with the 5 9L Cummins diesel engine After driving over 200 miles the fuel gauge
272. ol green stuff that we are all familiar with Yes HOAT coolant is backward compatible Again this issue has a detailed write up on all of the different types of antifreeze that are in use POWER STEERING Oops from the 1999 Owner s Manual here is another vague specification Only petroleum fluids specially formulated for minimum effect on rubber hoses should be used Mopar Power Steering Fluid 04883077 is a fluid of this type and is recommended Without a clear definition have defaulted to the Mopar part number However the Owner s Manual for a 2003 Turbo Diesel shows the proper fluid to be Mopar ATF 4 Ditto the 2007 manual So just as we saw with different manual transmissions there is not a one size fits all lubricant for truck s power steering When in doubt check the manual for your truck BRAKE FLUID Yes another easy item to cross reference The manual from my 99 Turbo Diesel reads Only brake fluid conforming to DOT 3 and SAE 1703 should be used DOT 3 fluid is easy to obtain The 2003 Owner s Manual shows DOT 3 DOT 4 or DOT 4 the 2007 manual shows the same CONCLUSION No doubt you noticed that there were differences in the specifications from the three Owner s Manuals 1999 2003 and 2007 that were the basis for this article Your Owner s Manual is the resource for the specifications Follow the book s recommendations Likely you also noticed the evolution of the lube oil specification
273. ommon part numbers Mopar Cummins Other Lift pump 5012209AB 3936316 Lift pump gaskets 5014230AB 3931059 Injection pump overflow valve 4883838AB 3932096 2417413093 now ends in 101 Bosch Gaskets for overflow valve 5015576AB 3935171 Metal return line ov flow to rubber line 4746641 3923171 Fuel filter to injection pump metal line 3936691 Rubber elbow fuel heater to lift pump pein Not handy oa cuore na we PaE uel 4897669AB N a N a Roll over valve fuel module 52127666 N a Roll over valve grommet 4002149 N a Pre filter screen kit 4762962 3845400S Fleetguard Fuel heater to heater base upper 3834185S Fleetguard Fuel heater element 3907766S Fleetguard Fuel heater harness 38437228S Fleetguard WIF water in fuel sensor 1994 1996 only 3831852 S Fleetguard A Publication of the TURBO DIESEL REGISTER 129 130 TURBO TIPS The following is a collection of tips minimal cost modifications and solutions found by Dodge Cummins Turbo Diesel owners in real life operation of their vehicles It is gleaned from previous issues of the Turbo Diesel Register and is sometimes edited for brevity and clarity The categories in this harvest of hints follow the system of classification used in Dodge s Technical Service Bulletins 3 REAR AXLE own be sure to mix thoroughly before pouring it into the TDR member John Holmes gives some tips for ensuring that rear differential lube is at the proper level following a differe
274. on is a vehicle leaning or low on the left front corner The repair involves the installation of a spacer 4322629 on the left coil spring to raise the left front corner approximately one inch Front spring spacer for two wheel drive trucks The condition is a vehicle leaning or low on the left front corner The repair involves the installation of a spacer 4322629 on the left coil spring to raise the left front corner approximately one inch Service manual revision for camber specification REAR AXLE TSB 03 03 95 5 5 95 03 02 93 5 7 93 A Publication of the TURBO DIESEL REGISTER MODELS 94 95 BR 92 93 AD SUBJECT DESCRIPTION Rear axle trac loc chatter This bulletin supersedes 03 01 94 7 8 94 and applies to trac loc Dana model 60 70 and 80 axles The symptom is chatter while turning corners The bulletin involves draining and refilling the axle with new fluid and trac loc additive It is important that gear oil 4796517 and trac loc additive 4318060 be used Launch shudder vibration For 1992 1993 131 or 149 wheelbase trucks Describes repair procedure to adjust the pinion angle of the rear end to eliminate vibration or shudder in the 1 2 shift made at medium to heavy throttle This TSB does not address wheel hop that occurs with manual transmission trucks at start off Wheel hop is a function of driveline spring wrap up because of high torque being exerted on the pinion shaft 23 CAT
275. oneous alarm The correction is a reflash of the FCM 08 004 03 02 03 DR Electro mechanical instrument cluster MIC erroneous indicator lamps 3 14 03 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 03 DR Alternator mounting bracket cracked 4 4 03 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 CATEGORY 9 ENGINE TSB MODELS SUBJECT DESCRIPTION 09 002 02 98 02 BR Crankcase breather overflow 3 11 02 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 th
276. or and time involved to remove the unit dictates that one should install a new sending unit rather than hope a repair would work Oops I ve gotten a bit ahead of myself I ve got you diagnosing the fuel tank sending unit but haven t given you some tips on removing the fuel tank much less the fuel tank module which houses the sending unit prefer to drop the tank from the truck rather than lifting the truck bed A tank with a couple of gallons can be a circus to balance even with a large floor jack and a four foot section of 2x12 or similar sized plywood so it s nice to drain the tank My Rube Goldberg tank drainer idea was first presented by TDR writer Joe Donnelly in Issue 37 page 45 Unfortunately many of us have bed mounted fuel tanks toolboxes fifth wheel hitches etc making the bed lift method impractical In that event run the fuel low and remove the filler neck it has a check ball in it so the hose won t snake down in to the tank Put a piece of 3 8 hose into the tank cut a whistle near the end and blow air through the whistle with compressed air This will start fuel flow and if your catch can is lower than the tank it will flow until the tank is virtually empty Hard plastic lines supply and return of a quick connect variety connect to the module and run along the frame rail this plastic line mates to a metal or braided line on some models The lines then mount onto a bell housing br
277. orts to write the perfect country music song by writing the perfect transfer pump article Jim responded Keep it simple try the catch phrase from the Millionaire show Is that your final answer Thus present the final answer perfect transfer pump article While the article focuses on the 98 5 02 owners this collection of TDR oldies also has tips for 94 98 12 valve owners and 03 07 HPCR owners The information was pulled from our Issue 32 48 and 50 magazines Updates have been added to reflect the latest part number information Then to add a final crescendo to the article lII share with you a story that will be of interest to 300 000 owners of 03 and 04 5 HPCR owners Below is an outline of the topics that will be covered e 98 5 02 trucks correct fuel pressure e 94 98 12 valve fuel transfer pump replacement e 98 5 02 24 valve fuel transfer pump replacement e Fuel pressure gauges and opinions e 98 5 02 24 valve fuel transfer pump relocation kit 98 5 02 24 valve what to do e 03 04 5 HPCR what to do 05 to current HPCR what to do Here we go CORRECT FUEL PRESSURE 98 5 02 TRUCKS In May of 2001 there was a great deal of concern about fuel transfer pump delivery pressures The problem first surfaced as a result of a production batch of inadequate transfer pumps and the resulting product recall Hand in hand with the recall was th
278. ote to the membership the primary parts package for this repair does not include a replacement ignition switch assembly but rather provides a blower motor relay and overlay harness if necessary an ignition switch wiring pigtail clips screws washers etc to install the blower motor relay During the repair the ignition switch and associated connectors are to be inspected The technician is instructed to look for indications of melting or deformation specifically at terminals four and five Very few vehicles are expected to require ignition switch replacement Editor s note The title of the recall Ignition Switch Recall 875 leads one to conclude that the recall is to replace the ignition switch assembly As summarized from the dealer service instructions the recall has very little to do with the ignition switch but rather is focused on adding a relay to the blower motor circuit The moral of the story don t jump to conclusions based on the title of a memo and be sure additional trailer light wiring and accessories that are added to your vehicle are on a separate relay switched circuit Ref 30 p 50 Glitch Go with no throttle Fix With all the racing antics and double clutching gear jammers it s no wonder the throttle cable on 94 96 trucks tended to wear out It might be the worn spring ball joints or the cable itself but a lot of TDR owners had trouble getting the throttle response desired This became
279. ou can borrow one from elsewhere on the engine When reinstalling your lift pump use the longer bolt as your starter bolt Once you get the lift pump and fuel heater partially tightened down install one of the original bolts in the other hole Once it is partially tightened remove the longer bolt and replace it with the other original bolt Tighten the two bolts to 18 ft lbs torque Tighten the two bolts alternately to prevent damage to the fuel pump housing thought this was the easier and less time consuming way than removing the starter and trying to be a contortionist by working my way around the front differential Next step bleed air from the fuel system Begin by loosening either doesn t matter which of the two 10mm bolts on top of the fuel filter housing This will allow the air to escape as you prime the system When priming the fuel system begin by pushing the primer button a few hundred times and when you finally feel like your thumb is about to fall off do it a few hundred more times Seriously don t use your finger to push the primer button My favorite tool for this job is a jack handle from one of those cheap automotive two ton jacks that has a slot in the center of the open ended pipe Another method that s been used at Geno s Garage is using an old broom handle to push the primer button decided to make my broom handle a little easier to use by taking a PVC coupling and sliding it on the end of the b
280. our weeks worth of research and was no better off than when started My quest was not clouded by the need for better transfer pump performance simply wanted a cost effective solution to a problem that could arise Solve the problem and provide others with a fairly priced alternative A Publication of the TURBO DIESEL REGISTER Sure could go the aftermarket transfer pump route at 400 or the aftermarket transfer pump with single or dual fuel filters as a part of the kit at 650 And as you know there is the factory answer that would cost about 850 could recite the numerous parts supercessions could send you on the same wild goose chase for the transfer pump that is used in other non Dodge B series engine applications But lIl save you some time the part is made by Airtex and the part number is 3968188 The price is 140 At Geno s Garage we found some brackets and had it ready for release as an alternative to the aftermarket and factory answers Then called Cummins to place an initial stock order You guessed it nationwide backorder At this point was exasperated So called Eric at Vulcan Performance www vulcanperformance com We discussed the cheap apprehensive lazy and incompetent man s options to solve the 03 04 5 transfer pump problem We tried to formulate an answer We discussed an inexpensive kit to relocate the fuel pump onto the frame rail underneath the truck We discussed many afterma
281. page 49 I removed the fuel filter assembly with the attached fuel heater and fuel pre filter from the truck applied 30psi of air to the assembly and lowered it into a bucket of water Instantly observed a stream of bubbles rising from the fuel heater electrical connector The connector had a crack in it causing the lift pump to suck air into the fuel system Without the removal of the assembly and the pressure test I m not sure would have found this rare problem The fuel heater warms the fuel if the fuel temperature is below 40 and shuts off when the fuel temperature reaches 80 The heater draws about 300 watts at 0 This should help to prevent fuel gel in sub zero climates Should your fuel heater fail it can be removed or eliminated The pre filter bowl is removed using a short 17mm box combination wrench and then a 8mm hex wrench is used to remove the shoulder bolt that retains it to the fuel heater casting Once the fuel heater is removed the pre filter bowl should spin onto the pre filter base the heater can be unplugged and you should be on your way The pre filter assembly is attached to the engine block with the transfer lift pump cap screws Fuel comes into the top of the unit via a short metal supply line which attaches to the short length of 3 8 fuel line It then passes through the 127 pre filter screen then the fuel heater then back out through a port and over to the transfer lift pump This
282. pair of pliers rotate the assembly counter clockwise to remove it from the gear case cover Remove the two 13mm nuts from the engine speed sensor RPM pick up Make sure to make note the orientation of the bracket and the placement of the wire hold down bracket Place the sensor off to the side making sure not to damage the sensor or the wires to the sensor Remove the engine vibration damper using a 15mm socket and inch drive breaker bar Using a 10mm socket remove all the gear cover bolts Two of these bolts are 8mm and it is best to use a wrench as these bolts are for the engine speed sensor Note there are long and short bolts they will need to be put in the proper locations when reinstalled Remove the gear cover Locate the dowel pin and look to see if it is fully seated Most of the pins will be flush with the gear housing or just below flush if they have not backed out If the pin seems to be backed out find a small punch With a hammer and punch tap on the head of the dowel pin and drive it into the block as far as possible Lucky step 13 Time to install the special egg washer preventive maintenance part Locate the 10mm bolt next to the dowel pin and remove it reinstall the longer bolt using the special washer supplied in the kit This washer will prevent the dowel pin from backing out Apply loctite high strength red thread locker to the threads and torque the bolt to 18 ft Ibs torque Using a gasket scr
283. panel retainer clips are separated from the door without using a trim panel removing tool 23 37 98 98 99 BR Cargo net eliminated from production 8 21 98 This bulletin applies to standard cab vehicles and informs the dealer network that the cargo net is no longer a production item It can be purchased through the parts department using Mopar number 04761197 23 58 98 99 BR Wind noise whistle around grill area and or dimples on the grill painted surface opposite of the 11 27 98 grill fasteners This bulletin applies to Ram trucks equipped with the sport package If there is a windnoise whistle occurring from the front of the vehicle at highway speeds between 45 65 mph or at slower speeds when driving into a headwind this bulletin describes the repair procedure A Publication of the TURBO DIESEL REGISTER 5 TSBs Issued During 99 CATEGORY 2 FRONT SUSPENSION TSB MODEL SUBJECT DESCRIPTION 02 06 99 94 00 BR Front wheel bearing grease is evident on the bearing seal area Rev A This bulletin supersedes TSB 02 06 99 dated June 11 1999 The revisions include the addition 12 17 99 of 4x2 models and additional model years This information only bulletin discusses the fact that front wheel bearings may be incorrectly diagnosed as faulty due to the evidence of wheel bearing grease on the bearing seal areas This grease purge is a normal design condition The factory fill of the bearings includes a slightly greater amo
284. ph 62 A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE Continued If intake manifold temperature IMT is less than 9 C 15 F three of the cylinders will be shut off upon reaching 1200 rpm creating a slight change in engine sound which is normal Thus the engine has to work to overcome the three dead cylinders This allows the engine to create increased heat in the cooling system allowing more rapid warm up Either feature will abort when any one of the following occurs The automatic transmission is placed in gear forward or reverse The service brake pedal is depressed Throttle position is greater than 0 Vehicle speed greater than 0 mph Coolant temperature is greater than 79 C 175 F CATEGORY 21 TRANSMISSION TSB MODELS SUBJECT DESCRIPTION 21 004 01 01 BR Overdrive disabled to improve transmission reliability during cold temperature operation 02 16 01 This bulletin applies to vehicles equipped with an automatic transmission where the vehicle was built on or between June 26 2000 and December 23 2000 and the PCM software level is earlier lower than calibration 14 for model year 2001 Quality analysis has determined that insufficient lubrication of certain internal transmission components may occur when a vehicle is operated in temperatures lower than 20 C 5 F This condition may be caused by the automatic transmission fluid ATF freezing in the cooler lines and interrupt
285. pplies 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 42 A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS SUBJECT DESCRIPTION 18 25 97 96 97 BR EGR system failure with Hex Code 2E on 5 9L Diesel 8 15 97 This bulletin applies to vehicles equipped with a 5 9L Cummins Diesel engine built between Jan 1 1996 and Dec 31 1996 with California emissions sales code NAE If while performing other diagnostics the technician notices Hex Code 2E EGR SYSTEM FAILURE on the Diagnostic Scan Tool DRB III the diagnosis outlined in the bulletin should be followed The customer may or may not experience any engine driveability symptoms The Malfunction Indicator Lamp MIL will not be illuminated The repair involves using revised test procedures to diagnose the EGR system and selectively erase and reprogram the Powertrain Control Module PCM with new software calibration changes for the condition listed Editor s note 2E is correct 18 29 97A 96 98 BR Vehicle bucking on 96 thru 98 truck
286. pplies to vehicles equipped with an automatic transmission where the vehicle was built on or between June 26 2000 and December 23 2000 and the PCM software level is earlier lower than calibration 14 for model year 2001 Quality analysis has determined that insufficient lubrication of certain internal transmission components may occur when a vehicle is operated in temperatures lower than 20 C 5 F This condition may be caused by the automatic transmission fluid ATF freezing in the cooler lines and interrupting the flow of lubricating oil ATF to the transmission overdrive unit This condition should be a concern only in areas where very cold ambient temperatures of 20 C 5 F are experienced The revised software will not allow 4 gear overdrive to occur if ambient temperatures are less than 20 C 5 F The revised PCM software has been implemented to improve transmission reliability The customer should be informed that reduced fuel economy would be expected when overdrive is not in use The repair involves selectively erasing and reprogramming the Powertrain Control Module PCM with new software calibration level 01Cal14 21 009 01 01 BE BR NV5600 Countershaft service 10 15 01 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 w
287. pressure needle out of the Schrader valve A Publication of the TURBO DIESEL REGISTER What Pressure Should I See The readings that am seeing on the gauge 13 14 psi at idle 12 psi 2000 rpm no load 11 psi 3000 rpm no load 10 psi 3500 rpm no load 10 psi various rpm 10 psi boost 8 psi various rpm 20 psi boost 3 psi various rpm 30 psi boost From the readings at idle and at various rpm with a load and a resulting boost reading that is at stock truck 20 psi or below levels the gauge checks out okay As push the performance envelope with my hot rodded engine i e the 30 psi boost reading the fuel pump is marginal Does the fuel pump meet the stock specifications Yes Is it ideal for my truck s hot rodded performance Good question In discussions with other hot rod owners find that the old adage I am my own warranty station once again proves correct As you increase the output power of the engine from its design the hot rodder has to look at upgrading other components Discussions with other owners have uncovered various solutions to the low pressure at high performance blues drilled out banjo bolts for better fuel flow bigger fuel lines different fuel pumps different pump locations The saga will continue A Publication of the TURBO DIESEL REGISTER FROM ISSUE 40 794 to 98 12 VALVE FUEL TRANSFER PUMP REPLACEMENT by Brandon Parks did not think fuel transfer pumps on
288. project and that 03 04 5 owners have a replacement part from the aftermarket This plug and play option means you don t have to use the factory suggested repair technique drop the fuel tank labor estimate 300 400 and add the 05 current fuel pump kit that goes into the fuel tank parts estimate 400 This article updates the 56 article Thus we add another chapter to The final Answer Perfect Transfer Pump article Robert Patton TDR Staff Related TDR articles Issue 56 Fuel Transfer Pumps Revisited This 14 page article covers 94 08 fuel transfer pump replacement options and service techniques A Publication of the TURBO DIESEL REGISTER 11 2008 Epilogue Attention 98 5 02 Owners Tired of reading about fuel transfer pumps No doubt that you are and if have done my job as a writer there is no doubt that you understand the important role the fuel transfer pump plays in the well being of your expensive Bosch VP 44 fuel injection pump The VP 44 injection pump has to have fuel pressure from the fuel transfer pump or it will fail in short order In your readings you may have also noted my frugal recommendations e Purchase and install a cost effective fuel pressure gauge 75 e Purchase a spare factory fuel transfer pump and kept he pump your tools and the instructions on how to change handy 150 In the fall of 2008 the folks at Diesel Performance Products the makers of the F
289. pump typically manufactured by Carter It is designed to provide about 25psi to the fuel filter It contains a manual primer and integral check valves that prevent prime loss and pressure delivery as fuel exits the pump The pump is actuated by a plunger tappet which rides on an eccentric engine camshaft lobe Often as the pump ages the check valves wear and the plunger springs weaken This can cause internal as well as external air and fuel leaks and a loss of fuel prime Additionally the fuel volume and or pressure can diminish to a level which will cause sub par engine performance A healthy lift pump provides a volume of fuel far in excess of what the Bosch P7100 injection pump can use with the exception being very high horsepower demands At 400 rpm starter motor cranking speed for a thirty second cranking duration the pump should deliver a volume of 20 oz of fuel 1 1998 12 valve illustration part number 13 differs on 1994 1997 designs The fuel exits the lift pump through a metal tube to the fuel filter base inlet It then is filtered and exits the outlet of the fuel filter assembly to travel to the injection pump It is desirable to see 25psi at the fuel filter inlet If you notice more than a 5psi drop across the filter inlet to outlet the filter is likely causing restriction When testing the lift pump should more than 4 0 inch Hg be shown on a vacuum gauge an inlet restriction exists somewhere back at the fuel tank Th
290. pward or full downward position The repair involves removing existing lubrication on the power seat track adjustment lead screws and then applying a new lubricant 23 35 99 94 00 BR Child seat tether anchors Rev A This bulletin supersedes technical service bulletin 23 35 99 dated September 3 1999 This 10 01 99 bulletin identifies the parts and labor operation numbers necessary to install a child seat tether anchor A Publication of the TURBO DIESEL REGISTER 55 TSBs Issued During 00 CATEGORY 2 FRONT SUSPENSION TSB MODELS SUBJECT DESCRIPTION 02 04 00 94 01 BR Squeaking clicking noise from rear leaf springs Rev A If the vehicle has a squeaking clicking noise coming from the rear of the vehicle verify that 05 12 00 the noise is coming from the rear springs as the vehicle s suspension goes through jounce and rebound If a squeaking clicking noise is coming from the rear springs perform the repair procedure The procedure involves replacing the spring tip liners and installing spring clinch clip insolators CATEGORY 5 BRAKES TSB MODELS SUBJECT DESCRIPTION 05 04 00 00 BR High pitched squeal from rear brakes 05 01 00 This bulletin applies to 2500 3500 series Ram trucks built before March 1 2000 The condition discussed is a high pitched squeal coming from the rear brakes when the brakes are applied The repair procedure involves installing revised rear brake shoes 05 06 00 00 01 BR Fro
291. question whether these kinds of CD media are being used When customers encounter these symptoms check the system with a known playable CD The media may not be compatible with some automotive CD players Replacing or exchanging the CD player will not address these issues 08 16 00 94 00 BR Front door speaker buzz 04 28 00 The bulletin discusses a buss noise coming from the front door speaker s The noise may be more noticeable while listening to talk radio segments with deep male voices The repair procedure involves installing a urethane foam pad between the inner door panel and the door trim 56 A Publication of the TURBO DIESEL REGISTER CATEGORY 8 ELECTRICAL Continued 08 17 00 99 00 BR Intermittent speaker operation static 05 12 00 Intermittent operation static may occur in any or all speakers The bulletin applies to vehicles equipped with the Infinity sound system sales codes RBR RBN and RAZ built before October 1 1999 This repair involves installing new speaker kits on both right and left front doors and installing foam between the inner door trim panel and the door 08 18 00 98 01 BR Radio Interference to from two way radio receivers 05 12 00 Customers may complain of intermittent poor reception on their two way radios This bulletin involves installing a RFI filter in series with the electric fuel pump motor 08 23 00 98 01 BR Plastic boot to protect the electrical harness B e
292. r 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 98 99 BR Slow acceleration or lack of power while towing or hauling a heavy load 05 28 99 This information applies to vehicles equipped with a 5 9L 24V diesel engine built before engine serial number 56587297 with a date of engine manufacture of May 5 1999 This information is available on the engine data plate which is located on the left side of the engine affixed to the gear housing There may be a condition of low power or slow acceleration when towing or when hauling a heavy load This software change to the Cummins CM551 diesel engine controller will increase engine torque Some 1998 BR vehicles equipped with a 5 9L 24V diesel engine may already have the latest software revision Verify that the ECM is at calibration level 98T17 p n s 333034303J 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 softw
293. r may experience an illumination on the instrument cluster of the ABS anti Lock Brake System and or the ESP BAS Electronic Stability Program Brake Assist System warning lights Investigation may reveal the presence of diagnostic trouble code DTC C1240 Steering Angle Sensor Over Travel Performance If the diagnostic test procedure for DTC C1240 determines that the steering angle sensor is at fault then perform the repair procedure Cell phone induced buzz or clicking like sound in radio speakers This bulletin involves a discussion regarding cell phone generated signal interference with the vehicle radio system A customer may experience a buzzing or clicking like sound coming from the vehicle radio speaker s The sound may be heard when the radio is in AM or FM mode The clicking like sound may sound like Morse code This information only bulletin points out that the construction of certain cell phones may generate frequencies that can interfere with the vehicle radio system These frequencies may result in buzzing and or clicking like sounds in the vehicle radio This condition can be easily corrected by instructing the customer to move their cell phone away from the immediate area around vehicle radio system radio radio amplifier antenna antenna lead Do not replace any radio system component in an attempt to address this condition A Publication of the TURBO DIESEL REGISTER CATEGORY 8 ELECTRICAL Continued 08 003 07
294. r should have looked closely at this fuel transfer pump s performance as knew it wasn t up to par The VP 44 bit the dust leaving me stranded at the drag strip Fuel Transfer Pump Failure After the installation of a Westach fuel pressure gauge the fuel transfer pump on my truck would only give a reading of 3 psi Having earned the degree of shadetree mechanic first looked at my workmanship with the gauge for the cause of the problem As a test bed for products sold at Geno s Garage the truck is equipped with two fuel pressure gauges one reading fuel pressure prior to the fuel filter the other reading fuel pressure after the fuel filter Yes they both showed 3 psi swapped the sensor leads and even tried a replacement sensor to see if the problem was with my workmanship The reading was still 3 psi Convinced that the transfer pump was the problem ordered a fuel transfer pump from Cummins Likely this could have been covered under the engine s warranty but did not have time to spare The latest Cummins part number is 3990082 the part numbers have been changing with much frequency The cost 160 The 3990082 kit includes a wiring pigtail to allow the pump to be used in all 24 valve applications also ordered four fuel line banjo bolt gaskets part number 3963983 at approximately 1 00 each Before examining the illustrations of the transfer pump let s refer to the Dodge Service Manual for their pump
295. ransmission are the same as those used in the 07 5 introduction of the Cummins 6 7 liter engine in January of 2007 The nomenclature for the automatic transmission is the 68RFE the nomenclature for the manual transmission is G56R The gear ratio comparison chart is found in the 2007 Turbo Diesel write up Commercial Chasis Cab models 3500 4500 5500 get the revised G56R manual transmission The Aisin AS68RC six speed automatic transmission is the same as the initial ofering of the first Chassis Cab 3500 model in March of 2006 Maximum Towing Capacities In the 2008 Ram Truck brochure the factory has gone back to the rating guidelines that they used in 2005 whereby they simply list the payload and towing weights With previous GCWR numbers the reader knows the maximum trailer weight plus the weight of the truck equals the GCWR Effectively the heavier the truck is the ess the trailer can weigh in order to not exceed the GCWR A Mega Cab Long Bed where did this truck come from A Publication of the TURBO DIESEL REGISTER The 2008 brochure does not list the truck weight or the TDR would do the math in order to present consistant data to you The data we have from the 2008 brochure is presented below Payload Trailer Weight 2500 Regular Cab 4x2 2 680 13 550 Regular Cab 4x4 2 270 13 100 Quad Cab 4x2 2 520 13 350 Quad Cab 4x4 2 070 12 900 Mega Cab 4x2 2 050 12 850 Mega Cab 4x4 1 520 12 350 3500 DRW equipped 4 10 axle
296. rature is less than 60 C 32 F Coolant Temp is less than 60 C 140 F The transmission is in Neutral or Park The Service Brake pedal is not depressed Throttle 0 Vehicle Speed 0 mph MMMM MM If intake manifold temperature IMT is less than 9 C 15 F three of the cylinders will be shut off upon reaching 1200 rpm creating a slight change in engine sound which is normal Thus the engine has to work to overcome the three dead cylinders This allows the engine to create increased heat in the cooling system allowing more rapid warm up Either feature will abort when any one of the following occurs The automatic transmission is placed in gear forward or reverse The service brake pedal is depressed Throttle position is greater than 0 Vehicle speed is greater than 0 mph Coolant temperature is greater than 79 C 175 F 18 014 01 98 02 BR BE Performance enhancement for severe cold weather environments 7 9 01 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 gr
297. re 02 09 07 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 21 006 07 05 DH Flash New 48RE feature that allows normal shift schedule with full disable of 4th gear 03 20 07 overdrive This bulletin applies to vehicles equipped with a 5 9 liter Cummins Turbo Diesel engine and a 48RE automatic transmission sales codes ETH and DG8 respectively Anew 48RE transmission feature is added that will allow normal shift schedule with full disable of 4th gear overdrive gear when the customer selects the Over Drive O D switch Prior to the implementation of this new transmission feature the use of the O D switch changed the automatic transmission shift schedule from 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 0
298. re 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 03 DR No throttle response lack of power while towing and diagnostic trouble codes DTC P2638 7 4 03 P0700 The bulletin applies to vehicles equipped with a Cummins diesel engine sales code ETC or ely 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 98 5 02 BE BR Generic Cummins engine control module ECM procedure 8 29 03 03 04 DR 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 R
299. removal instructions When read Step 3 remove starter motor knew two things One don t have a service bay with a hydraulic lift allowing access to the starter motor and transfer pump from underneath Two would not be doing the job as outlined in the Service Manual Sounds like an opportunity to rewrite the manual Can this job be accomplished from above You bet and it is not as difficult as one might imagine Follow the pictorial for tips on how to do it A Publication of the TURBO DIESEL REGISTER Step 1 This step is not pictured but itinvolves the common sense recommendation of disconnecting and pushing the oil dipstick tube and other related cables and wires out of the way of my access from above service location Step 2 Remove the fuel supply line from the transfer pump From the bench picture you can see the two blue quick connects that you push in to release the fuel supply line The fuel line to the transfer pump and the fuel line that goes to the fuel tank are pictured here Step 3 Disconnect the transfer pump s wiring harness Step 4 Disconnect the supply to filter assembly fuel line from the transfer pump A 17 mm stubby wrench works wonders for the removal of the banjo bolt holding the fuel line to the transfer pump m 112 Step 5 Loosen the three 15mm nuts that hold the transfer pump to the bracket Remove the 10mm bolt that positions the fuel line to the bracket R
300. res 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 94 96 BR Revised power brake booster check valve 12 31 99 This bulletin applies to vehicles equipped with the 5 9L Cummins diesel engine A revised power brake booster check valve p n 05011393AA has been released for service The new check valve performance has been improved by changing the flapper style check valve to a spring loaded style check valve The spring loaded style check valve performance is superior especially in vehicles that utilize mechanical vacuum pumps to provide the vacuum source to operate the power brake booster Part number 05011393AA should be used any time the power brake booster check valve is serviced on the subject model vehicles 50 A Publication of the TURBO DIESEL REGISTER CATEGORY 8 ELECTRICAL TSB 08 06 99 Rev A 12 17 99 08 16 99 6 11 99 08 17 99 05
301. rket pumps that could be used in the new frame rail location the Cummins Airtex the old Cummins Federal Mogal 24 valve design Walboro Carter and Holley Then we agreed that none of these fuel pumps offer the 03 04 5 customer a proven record of performance As a plug and play option understand that Delphi offer a replacement The part number is FP943 Several TDR vendors offer this unit Diesel Injection www dieselinjection com and Scheid Diesel www scheiddiesel com are two locations that am aware of The retail price is about 450 was pushed to consider the aftermarket The installation requires hardware and fuel lines to relocate the transfer pump to the frame rail underneath the truck Several TDR vendors and their dealers offer relocation kits and pumps in prices that range from 400 and up depending on the pump s performance and whether or not you want additional filtration Vendors that am aware e Vulcan Performance www vulcanperformance com e Diesel Performance Products FASS system www dieselpp com e Pureflow Technologies AirDog system www pureflowtechnologies com e Glacier Diesel Power www glacierdieselpower com Also there are many dealer outlets that offer these vendor kits At this juncture the aftermarket is the cost effective answer A Publication of the TURBO DIESEL REGISTER 05 07 WHAT TO DO Starting with the 05 model year the fuel transfer pump was relocated into the fu
302. rly priced Be glad you re not a PowerStroke owner where the price for a 6 0 liter engine fuel filter package is 55 How about the Mopar boxed fuel filter kit In fact the Mopar part is made by Fleetguard However would you believe the Geno s folks sell the kit for 10 That is not a typo the Geno s staff knows that their price from their Dodge dealership is too low and not correct Being forthright they advised the Dodge dealership and the dealership advised Mopar Oh well Owners of the 6 7 liter truck should take advantage of this pricing glitch while you can The folks at Geno s will honor the price as long as possible They have 500 filter kits in stock Asa postscript received a follow up phone call from Fleetguard The response The plastic cartridge unit was not designed as a lifetime product As such there has not been validation done to substantiate the cartridge s use long term So the final answer There is not much hope for a fuel filter only so get em the mis priced Mopar fuel filter kit while you can 125 126 LOW PRESSURE FUEL SYSTEM PROBLEMS by Andy Redmond We all see much discussion on the TDR web forums and in the TDR publications regarding performance drivability issues which are often traced to a low pressure fuel delivery problem Although the narrative that follows is specific to the 12 valve Turbo Diesel trucks model year 94 to early 98 pre 24 valve engine th
303. roblem but adding a relay to take all the added load does If you use a camper or pull a trailer you might consider adding a ground switch to the rear lights on your truck so that they do not reflect in your mirrors when backing up or when the camper is onboard In late 2001 there was a recall issued for 94 to 96 model year trucks covering problems associated with the ignition circuit and the truck s blower motor This important recall information follows 101 102 Ignition Switch Wiring Recall 875 The ignition switch and or steering column wiring on about 710 000 of the above vehicles 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 and airbag lamp illumination or a steering column instrument panel fire The vehicles involved in the recall have a vehicle identification number as follows Warren S in the 11 VIN position through April 4 1996 St Louis J in the 11 VIN position through March 23 1996 Lago Alberto M in the 11 VIN position through April 14 1996 Saltillo G in the 11 VIN position through April 14 1996 The repair involves installing a blower motor relay and overlay harness to remove the blower motor circuit from the ignition switch In addition the ignition switch and electrical connector must be inspected for damage and replaced if necessary N
304. roblem occurs where the hose connects to the 4WD shift collar Of course your engine doesn t draw a vacuum but a pump generates it to power some brake boosters most HVAC systems which default to Defrost as a safety issue and on Second Generation and later 4WD models the front axle disconnect system The vacuum hose is cheap and easy to find regardless of the size Ref 39 p 40 Glitch ATF drools Fix Although a number of things could be to blame the first place to look was always the plastic fittings on the transmission fluid cooler lines on 94 96 trucks Sooner or later these got brittle from being overheated and expired allowing the transmission to pump its fluid all over the road The fix involves changing the plastic line retainers to Weatherhead fittings Dodge also offered an upgraded set of lines with metal clips On 94 98 models the transmission lines crossed on the bellhousing At the cross point the metal lines rubbed together and wore a hole in one line thus causing loss of all ATF fluid After replacing the lines owners installed rubber hose over the lines to keep them apart and prevent vibration rubbing Ref 17 p 30 I 21 p 39 1 35 p 45 A Publication of the TURBO DIESEL REGISTER Glitch My truck s dripping fuel this time and it s hard to start Fix Fuel out often means air in and most diesels will be hard if not impossible to start with air in the fuel lines The hoses around th
305. rol cable may not allow the throttle to return to the idle position In addition the throttle control linkage joints may corrode and cause the throttle to bind or stick Either of the above conditions could increase the truck s stopping distance and cause an accident without warning DaimlerChrysler will repair your truck free of charge parts and labor To do this your dealer will replace your truck s throttle control cable and throttle linkage The work will take about 1 0 hour to complete The service repair procedure A Publication of the TURBO DIESEL REGISTER involves removal of the throttle control cable throttle linkage rod ends and linkage ball studs as all of these parts are replaced Detailed removal and reinstallation instructions are provided to the dealership reference Safety Recall 970 If you have already experienced the problem described above and have paid to have it repaired you may send your original receipts and or other adequate proof of payment to the following address for reimbursement DaimlerChrysler Customer Assistance Center PO Box 1040 St Charles MO 63302 1040 Attention Recall Center UPPER CONTROL ARM FASTENERS Recall 955 2001 BR BE Ram Truck Quad Cab manufactured in July 2000 The upper control arms attached with cadmium coated nuts can cause the bolts to stretch due to the application of a higher than specified clamp load Breakage of the upper control arm fasteners could cause the a
306. room handle and drilling a hole about a 1 8 below the top ridge and installing a bolt in it This is to help prevent the rubber boot from tearing This will always come in handy when you have to prime the fuel system When you hear the fuel hit the pump try starting your truck cH eM Wah t Overall it was a fairly easy installation Skill level give it a five on the 1 to 10 scale make that a three you know the shortcuts Using the longer bolt and the broom handle made it much easier Brandon Parks Geno s Garage A Publication of the TURBO DIESEL REGISTER FROM ISSUE 34 98 5 to 02 24 VALVE FUEL TRANSFER PUMP REPLACEMENT by Robert Patton In two previous Issues of the TDR we ve followed the editor s difficulties with his 24 valve engine self inflicted VP 44 fuel injection pump failure Issue 30 page 36 marginal fuel transfer pump performance Issue 32 page 39 In this issue we continue the saga with the replacement of the fuel transfer pump Hindsight is 20 20 With the marginal performance of the fuel transfer pump should not have installed the performance module and then drag raced the truck The Bosch VP44 fuel injection pump needs fuel for lubrication and for cooling With its acknowledged marginal performance would the VP44 fuel injection pump fail As you increase the power output of the engine from its intended design the hot rodder has to look at upgrading other components This hot rodde
307. rovisions of warranty 08 35 97 98 BR Dead battery from ignition off draw IOD 9 26 97 The problem described is a dead battery due to the glove box lamp remaining illuminated when the glove box door is closed The proper diagnosis involves performing an ignition off draw IOD test as described in the 98 Service Manual If necessary the bulletin outlines the installation of two spacers between the glove box lamp switch bracket and the instrument panel glove box opening upper reinforcement 08 39 97 98 BR Remote keyless entry transmitter batteries discharge prematurely 11 28 97 This bulletin applies to vehicles built prior to August 15 97 and describes a condition where the Remote Keyless Entry transmitter batteries discharge in approximately 6 weeks The repair calls for replacement and reprogramming of the transmitter CATEGORY 11 EXHAUST TSB MODELS SUBJECT DESCRIPTION 11 01 97 94 97 BR Whine or howl while driving at highway speeds 5 16 97 This bulletin applies to vehicles equipped with the diesel engine option Some vehicles may experience a whine or howl noise while driving at highway speeds This noise may be miss interpreted as turbo whine After proper diagnosis of the condition the bulletin s repair procedure involves replacement of the muffler CATEGORY 14 FUEL TSB MODELS SUBJECT DESCRIPTION 14 07 97 94 97 BR Diesel fuel injection pump tampering 7 18 97 This information only bulletin a
308. rs should be treated as contaminated and replacement of the entire A C refrigerant system is recommended 24 004 03 03 DR Defrost door inoperative 6 13 03 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 14 A Publication of the TURBO DIESEL REGISTER 03 04 05 06 07 08 TECHNICAL SERVICE BULLETINS This combined section represents our review of Dodge Technical Service Bulletins TSBs issued to date 8 2008 Previously Dodge vehicle TSBs were published in CD format and were available for purchase in July August As a service we would purchase the TSB directory and then search through the CD to isolate only those bulletins relating to the Turbo Diesel truck The TSB directory is no longer available However the service that replaces it is an improvement Armed with your truck s vehicle indentification number VIN and a credit card you can log on to www techauthority com and for 20 you can view print all of the TSBs that apply to your vehicle Using several VINs from years 2003 to 2008 we downloaded the TSBs and have summarized the subject the description of the problem a
309. s and options are required to tow the intended weight then stick to inspecting trucks which meet those criteria Your familiarization session will lead you to ask the right questions when you visit the dealer lot or make contact with private sellers Next check the used vehicle value guides Most banks and other agencies that make car loans will have a variety of used vehicle value guides such as the Kelly Blue Book or NADA book that list wholesale retail and loan values for each model each accessory and offer mileage compensation factors These books are filled with option facts and regional pricing so can serve as a useful guide to true worth For those with a computer walk your fingers across a computer keyboard and visit the various web sites that offer needed information These include Kelly Blue Book kbb com NADA used truck guide NADA com carprice com edmunds com and others The dot com sites often track actual prices paid for trucks in your area or in a nearby metropolitan area If you want to research a particular truck web sites exist that allow you to check a particular serial numbered truck for lost stolen totaled reconstructed etc titles carfax com for a nominal fee You can also determine if a vehicle has been included in federal safety recalls by visiting several other sites Mining information from the web can be rewarding though time consuming but the more thorough your research at this stage the more i
310. s built prior to 8 15 97 If applicable the repair procedure involves replacing a park brake release lever with a revised part CATEGORY 7 COOLING TSB MODELS SUBJECT DESCRIPTION 07 03 97 All Engine coolant usage 5 9 97 This information only bulletin discusses the use of propylene glycol instead of ethylene glycol coolants CATEGORY 8 ELECTRICAL TSB MODELS SUBJECT DESCRIPTION 08 01 97 96 97 BR JTEC powertrain control wiring harness connector repair packages 2 3 97 If a dealership determines that a powertrain customer complaint could be related to a poor electrical connection the PCM connectors should be inspected The bulletin describes an assortment of electrical connector and terminal repair components that are available to aid in powertrain electrical wiring repairs 08 21 97 94 97 BR Engine failed to crank no start 5 23 97 This information only bulletin discusses a condition where the engine does not crank over when the ignition is placed in the start position The shop should then refer to the appropriate 97 Service Manual for proper diagnosis of the starter motor s electrical circuit A Publication of the TURBO DIESEL REGISTER 4 _ CATEGORY 8 ELECTRICAL Continued 08 22 97A 96 97 BR Inoperative speed control 7 11 97 This bulletin supersedes TSB 08 22 97 dated 6 20 97 The problem covered by the bulletin is an inoperative speed control due to a vacuum supply hose that is loose leakin
311. s on 16 tires Rear suspension is 60 long semi elliptic leaf springs on a rigid axle of varying capacity ratings by model for improved ride quality Two axle ratios are offered 3 54 and 4 10 1 Three rear axles are offered Dana 70 for 2500 automatics hybrid Dana 80 for 2500 manual and Dana 80 for 3500 trucks and cab chassis trucks The long tapered rear springs offer a smoother less choppy ride over rough roads The truck bed is rigidly mounted to the frame and is only offered as a sweptside design 8 foot box The bed also features indents in the bed to allow building a framework to carry multi tiered loads Bed tiedown mounts are standard front and rear The tailgate is detachable Engine Ratings The Cummins B 5 9 diesel was offered in two horsepower torque ratings 175HP 420 ft lbs torque for manual transmissions and 160 400 for automatic transmissions New is an inline Bosch fuel injection pump designated P7100 Intake air plumbing has been re designed for greater airflow The turbocharger is a wastegated design Transmissions Five speed manual NV4500HD 5th overdrive 450 ft lbs input torque capacity Four speed automatic 47RH 4th overdrive with locking converter 380 ft lbs torque capacity Looking Back Being an all new model this truck had a number of teething problems which resulted in both federal safety recalls and factory TSB fixes Chief among recalls was a fix for keys sticking in the backside of the steering
312. s with the Cummins engine and a manual transmission 12 5 97 with Cummins engine This bulletin supersedes TSB 18 29 97 dated 10 17 97 The condition to be corrected is one where and five speed the vehicle may exhibit a bucking or jerking condition while under light acceleration or while driving transmission at steady state speeds The vehicle may be in a loaded or unloaded state when the bucking or jerking occurs This condition results from the sensitivity of the throttle linkage to driver input The repair procedure involves replacement of the throttle linkage levers with revised parts CATEGORY 19 STEERING TSB MODELS SUBJECT DESCRIPTION 19 08 97 96 97 BR Clunk rattle felt in steering column wheel 5 30 97 This bulletin supersedes TSB 19 01 96 dated 2 9 96 for 1996 model year vehicles This bulletin applies to all vehicles built in the United States first digit of VIN 1 and vehicles built in Mexico first digit of VIN 3 before Mar 3 1997 The condition to be examined is a clunk or rattle that maybe felt in the steering wheel column during slow turns rough road driving 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 94 98 BR Steering wander 8 15 97 If when driving on a straight road a
313. scribes the inspection test repair or replacement of the DPF based on the severity of the accumulation in the DPF A Publication of the TURBO DIESEL REGISTER 81 CATEGORY 11 FRAME BUMPER Continued 11 001 08 07 08 DH D1 Cleaning the turbocharger on the Cummins 6 7 liter engine 5 21 08 2500 3500 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 07 08 DH D1 Inspections and test for the turbocharger on the Cummins 6 7 liter engine 5 21 08 2500 3500 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 CATEGORY 13 FRAME BUMPER TSB MODELS SUBJECT DESCRIPTION 13 001 03 03 DR Frame alterations 2 7 03 This bulletin is to support the 2003 Body Builder s Guide and presents guidelines that must be
314. se 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 A Publication of the TURBO DIESEL REGISTER in the brake line affecting brake effectiveness increasing the risk of a crash Dealers will replace the front brake hose assemblies and the ABS sensor wire will be inspected and replaced if necessary CLOCKSPRING Recall 982 2001 BR BE Dodge Ram Truck manufactured from May 2000 To October 2000 Sound deadener material internal to the clockspring could become detached from the clockspring cover and housing When this occurs the material could interfere with the clockspring ribbon and cause an open circuit The driver air bag system will become disabled and the air bag warning lamp will illuminate on the instrument panel Dealers will replace the clockspring assembly CUSTOMER SATISFACTION NOTIFICATION NO C44 TRANSMISSION COOLER LINE Date February 2004 Models 03 04 DR This notification applies only to trucks equipped with a 5 9 liter Cummins diesel engine sales code ETC or ETH and an automatic transmission sales code DG8 or DGP built through November 24 2003 The transmission cooler line on about 97 000 of the above vehicles can transmit high pressure pulses when the vehicle is operated at heavy loads These pulses may cause the engine mounted transmission cooler to crac
315. securing the ID plate with additional rivets 23 025 03 03 DR Scratched aftermarket window tint film 10 24 03 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 A Publication of the TURBO DIESEL REGISTER 91 CATEGORY 23 BODY Continued 23 001 04 03 DR Bug deflector wind whistle 1 13 04 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 23 003 04 02 04 DR Water leak at grab handle 1 27 04 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 deflec
316. sents a problem as tapping into the fuel system is no longer as easy as removing a 1 8 NPT plug The first solution that we offered called for replacing one of the fuel system banjo bolts with a bolt that was drilled and tapped to accept a 1 8 NPT pressure sending unit Unfortunately none of the banjo fittings are located in a vertical position Common sense dictated that mounting a 6 ounce sending unit that is on an angle into a fragile banjo bolt on an engine that vibrates is not a good idea At first we suggested that customers purchase a 1 8 NPT hydraulic whip hose for a grease gun and use the hose to plumb from a tapped banjo bolt to a mounting point for their Westach pressure sending unit As the technique evolved TDR member John Holmes developed a hose that would screw onto the Schraeder valve test port and also screw onto the 1 8 NPT male Westach pressure sending unit After several generations of hoses the Geno s group now offers a universal hose kit to access the fuel system s pressure Customer Wow that s a story It is now easy to understand the answer for 24 valve customers GG For 98 5 and 99 owners all that is needed is the Westach electronic fuel pressure gauge and an acceptable gauge mount The 00 to 02 owners should purchase a universal fuel line a Westach gauge and an acceptable gauge mount Customer Do you have any suggestions about transfer pump replacement for the 98 5 to 02
317. side Although some will dwell on the problems the majority of owners take initiative to solve correct anticipate prepare for a future situation That s what the TDR is all about Thanks to the TDR membership group and the support from DaimlerChrysler and Cummins we are equipped with answers and solutions rather than wonderment and isolation that would exist without a support group My thanks goes out to the TDR members for being a supportive membership group DODGE TECHNICAL SERVICE BULLETINS With the brief introduction out of the way this is our review of Dodge Technical Service Bulletins issued in the previous years For a given calendar year all Dodge vehicle TSBs are published in book format and are available for purchase in July August As a service we purchase the TSB directory and then search through the book for only those bulletins relating to the Turbo Diesel truck In an effort to consolidate the TSBs for the magazine we use the same index system categories as DaimlerChrysler Below are the index categories 2 Front Suspension 14 Fuel 3 Rear Axle 16 Propeller Shafts amp U Joints 5 Brakes 18 Vehicle Performance 6 Clutch 19 Steering 7 Cooling 21 Transmissions 8 Electrical 22 Wheels amp Tires 9 Engine 23 Body 11 Exhaust 24 Air Conditioning 13 Frame amp Bumpers 26 Miscellaneous A note concerning the TSBs and their use the bulletins are intended to provide dealers with the latest repair information
318. sing 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 A Publication of the TURBO DIESEL REGISTER 5 CATEGORY 14 FUEL TSB MODELS SUBJECT DESCRIPTION 14 01 00 00 BR Thump bump sound heard 1 3 seconds after the vehicle comes to a stop 02 04 00 This bulletin applies to 2500 series Club Quad cab vehicles equipped with the 6 foot box built before December 1 1999 Customers may hear a thump bump sound that occurs 1 3 seconds after the vehicle comes to a complete stop In some cases the thump bump sound may be transmitted through the floor of the vehicle allowing the customer to feel the thump bump in the floor pan of the vehicle The sound will only occur when the fuel level of the vehicle is between and 7 8 tank of fuel Since the fuel level of the vehicle must be between 7 to 7 8 full the condition may be difficult to diagnose The repair involves replacing the fuel tank 14 02 00 00 01 BR Crack in diesel fuel filter housing cover caused by an improper servicing procedure 04 14 00 This bulletin applies to vehicles equipped with a 5 9L 24V diesel engine built before engine serial number 56686747 with a date of manufacture of February 09 2000 Analysis of returned fuel filter housing covers has determined that a
319. soap and used coffee grounds Just put some of each in your hand add water and then scrub till your hands are clean BODY WORK When sanding inside curves wrap sandpaper around an old piece of radiator hose or other thick walled hose of the correct diameter You ll get a smooth material removal Planning to put a wild paint scheme or set of stripes on your truck but you re not sure how it will look Take some pictures of the truck have them blown up to 8x10s then use water based colored markers to draw the different schemes on the pictures The indented bottom of a soft drink can makes a good place to mix up a small batch of two part epoxy The handle of a small plastic spoon or fork makes a good stirring stick and an applicator Old gaskets can be tough to remove from parts even with a scraper Chuck a wire wheel into your electric drill and brush them off clean Be sure to wear safety glasses TAPE TRICKS An easy way to keep grease from your hands and other dirt off new brake shoes during installation is to cover the shoe surface with masking tape Remove the tape before you re install the brake drums Masking tape or duct tape wrapped around the ends of the U joints on a driveshaft keeps the bearing caps in place while handling the shaft GET THE RIGHT SIZE THE FIRST TRIP Determining the outer diameter of a piece of tubing or a bolt is easy Just slip the appropriate size open end wrench over the tubing t
320. ssity 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 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 72 degree to ensure that there will be some movement in the U joint bearings 03 004 04 03 04 DR Axle whine 6 22 04 This bulletin applies to 4x2 2500 series 140 5 inch wheelbase vehicles equipped with diesel engine sales code ETC ETH and an automatic transmission sales code DG8 The problem is that some vehicles may exhibit rear axle whine at speeds between 35 and 70 mph The repair procedure involves identification of the pinion flange and propeller shaft that the vehicle is equipped with If a repair is necessary
321. st manifold retention straps for 24 valve trucks Issue 38 page 84 Replacement engine parts from Cummins at a lower price than quoted by my local dealership various magazines First Generaton hood cowl repair Issue 34 page 58 Issue 33 page 41 First Generation Getrag gearbox lubricant overfill Issue 38 page 40 Throttle position sensor repair Issue 37 page 46 Installation of a torque converter lockup switch Issue 23 page 23 Grid heater dims the lights Issue 23 page 22 Cleaning the fuel filter s pre screen assembly Issue 38 page 45 Issue 35 page 85 Starter rebuild kit Issue 37 page 151 Automatic transmission lines and the problems with the plastic fittings quick connects Issue 21 page 39 A Publication of the TURBO DIESEL REGISTER Understandably survey respondents and the editor had a difficult time differentiating between a self contained tip and an article I ve tried to break them out into the appropriate category Regardless l II reemphasize that the text may prompt a reread and thus additional meaning to you An interesting point that noted is that the favorite article best tip references were from TDR magazines that were less than two years old which indicates that there is a limit to the shelf life of the magazine However rather than recycle technical data that is past the two year shelf life we will try to bring back articles that are still relevant often appearing in The
322. supplement to help the technician troubleshoot loose or worn steering components The track bar ball joint previously did not have an inspection procedure CATEGORY 3 REAR AXLE TSB 03 02 96 5 10 96 03 03 96 8 16 96 MODELS SUBJECT DESCRIPTION 94 96 BR Shudder when pulling away from stop when operated at maximum GVW rating 2500 and 3500 4x2 The bulletin is a supersession of bulletin 16 01 94 If the vehicle exhibits a driveline shudder while trucks regular cab pulling away from a stop at maximum GVW rating the bulletin describes the replacement of the automatic transmission two piece driveline and center support bracket with a single piece assembly and two piece propeller shafts 94 96 BR Droaning noise vibration With automatic The symptom typically occurs at maximum load and is engine speed specific 1900 rpm for 4x2 transmission and 5 9 models 1850 rpm for 4x4 models with the truck in fourth gear and the torque converter clutch Turbo Diesel engine locked up If the problem is identified a repair procedure involving a revised propeller shaft with Note 96 2500 club a yoke weight damper is described cab 155 WB 4x4 with heavy duty transfer case built after 5 9 96 have the revised propeller shaft A Publication of the TURBO DIESEL REGISTER CATEGORY 5 BRAKES TSB MODELS SUBJECT DESCRIPTION 05 14 95 A 95 96 BR Brake pedal noise when depressed 2 9 96 The symptom is a squawk type
323. t 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 98 02 BR Engine oil pan gasket sealing 08 24 01 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 98 02 BR Crankcase breather overflow determined 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 oper
324. t system enhancements 3 13 08 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 CATEGORY 19 STEERING TSB MODELS SUBJECT DESCRIPTION 19 005 03 94 02 BR BE Power steering fluid usage 8 29 03 02 04 DR 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 19 008 03 03 DR Vibration in steering column 11 28 03 Avibration 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 04 05 DR Power steering fluid contamination 11 29 04
325. t were not built with the trailer tow package Several changes to the trailer tow wiring have occurred since the truck was introduced It also identifies flashers This bulletin identifies the part numbers for the Mopar trailer tow packages required to adapt trailer wiring to a vehicle that did not have the trailer tow package installed as original equipment from the factory 08 47 96 97 BR Radio interference from buzzer module 12 20 96 The condition is a buzzing noise in the rear radio speakers with the radio on ignition on and the door ajar If a buzzing noise is heard the repair involves replacing the buzzer module A Publication of the TURBO DIESEL REGISTER 37 CATEGORY 9 ENGINE TSB MODELS SUBJECT DESCRIPTION 09 07 96 94 95 BR Fuel injection pump oil supply bushing oil seepage 6 7 96 If oil seepage is diagnosed the bulletin describes the repair procedure using a special oil supply and removal tool CATEGORY 11 EXHAUST TSB MODELS SUBJECT DESCRIPTION 11 05 96 94 97 BR Diesel turbocharger diagnostic procedure 8 23 96 This information only bulletin guides the service technician thorough troubleshooting steps to properly diagnosis turbocharger situations Normal abnormal noises oil leakage acceleration and low boost are topics discussed in the bulletin CATEGORY 14 FUEL TSB MODELS SUBJECT DESCRIPTION 14 07 96 94 96 BR Low pressure fuel system diagnostic procedures 8 2 96 Too low a fuel supply to
326. tail cleanliness the door jambs A clean door jamb typically indicates a vehicle that has been fanatically maintained Wear should be commensurate with mileage Look underneath the body for caked mud and dirt This indicates off road operation or an unintentional trip into the ditch Look under the hood Lots of dirt can indicate severe use and little maintenance Check for worn or chafed hoses oil leaks coolant leaks etc Pull the dipsticks and check fluid colors and condition Sight down the body sides to see if the panels are smooth If they re wavy the truck has been wrecked and further inspection underneath will reveal the severity of the accident Paint color differences between panels and or variations in body seam gaps also indicate a wreck in the truck s past Inspect tires for uneven wear to determine if there are suspension or axle problems This can also be an indicator of improperly repaired wreck damage Look for lube drips from the underside of the engine transmission and axles Seal repairs may have to be made A light oil drip or evidence of misting near the engine road draft tube is normal Look in the glove box and console to see if any maintenance receipts or records have been left behind and compare them with what you see Go for a ride and note if the engine idles smoothly and pulls strongly Do the transmission and clutch work as intended Does the automatic transmission shift without slipping or hangin
327. tem 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 95 96 BR Vacuum system contaminated with engine oil 10 11 96 With engine serial Some Turbo Diesel trucks were produced without a check valve on the vacuum pump Without a number 56230585 thru check valve oil may enter the vacuum system A visual inspection of the HVAC system is presented 56293178 or 45232867 and the repair procedure outlined thru 45360437 These engines were installed befor 6 1 96 YOU MIGHT BE A FORD CHEVY OWNER IF You write off a radiator as a business expense Your truck is insured by Smith amp Wesson There is a puddle in your driveway year round Your stereo speakers used to belong to the Moonlight Drive in Theater Your wife has ever said Come move this transmission so can take a bath You ve ever hit a deer with your truck deliberately There are more than four hats in the rear window of your truck Directions to your house include turn off the paved road 1 2 3 4 5 6 You read the Auto Trader with a highlight pen 7 8 9 10 Your hood ornament used to be a bowling trophy From You Might Be A Redneck If by Jeff Foxworthy Foxworthy s Southern humor can be found at book stores everywhere Buy his books for some serious fun 40 A Publication of the TURBO DIESEL REGISTER TSBs Issued During 97
328. th a strap wrench The Sidewinder also keeps your hands clean when removing the oil pan drain plug Barely loosen the A Publication of the TURBO DIESEL REGISTER plug with a standard 3 8 drive ratchet then switch to the sidewinder and twist the T handle to avoid having hot oil run down your arm as the plug is loosened Edmund Turner Jr An easy and clean way to drain the engine oil is to loosen but not remove the drain plug Oil will come out of the pan through grooves cut in pan sides if the plug is loosened by more than two turns Then you don t have to fish in the drain pan for the plug and gasket Louis Barnhart Oil changes become even simpler and cleaner with the addition of an inexpensive accessory called the EZ change drain plug which replaces the standard drain plug By screwing on a special hose adapter at drain time the plug s drain valve automatically opens and the draining oil is directed through a hose to the drain pan Removing the drain tube reseals the plug The plug kit is available from Geno s Garage Call 1 800 755 1715 Away to loosen a tight oil filter or canister type fuel filter is to take a long flat blade screwdriver place it on the filter rim at the proper angle and strike it several times with a hammer to drive the filter in a counter clockwise direction Louis Sytsma It is easier to pour new oil into your engine if you make your wobble proof funnel from a used plastic 1 75 liter Skol Vod
329. that he has Ford sponsorship I m hopeful the answer is yes and Kevin Cameron s technical discussions on all things mechanical Particularly valuable articles include the following Third Generation Overview Issue 36 page 62 28 by writers St Laurent and Anderson various articles on the 12 valve engine dowel pin problem and its solutions Issue 33 page 46 Issue 37 page 16 Issue 38 page 136 and Issue 40 page 56 and 148 by writers Donnelly Anderson Timochko and Kilby could continue reporting the positive comments and generalizations butthe purpose of this article is to summarize and mention issue numbers and page references so that you might revisit the article as a learning experience The following are some of your favorite articles Million mile trucks Issue 41 page 60 Issue 40 page 90 Issue 33 page 23 Issue 28 page 22 24 valve lift pump saga Issue 34 page 47 Issue 36 page 22 Issue 37 page 48 Issue 38 page 46 24 valve lift pump replacement Issue 34 page 48 12 Valve hard start no start Issue 41 page 16 and 38 Issue 38 page 42 Issue 36 page 36 Economical operation of the diesel engine Issue 29 page 30 Gauge evaluation Issue 34 page 20 Oil Filter evaluation Issue 32 page 36 Exhaust brake installation and 12 valve valve spring change out Issue 36 page 30 and 124 12 valve valve adjustment Issue 29 page 44 First Generation best tips Issue 39 page 34 Clutches and dr
330. the 94 to 98 12 valve engines The dowel pin is not a problem on 24 valve engines as the timing cover was changed to fit the 24 valve s VP44 fuel pump These 12 valve engines have the heavier Bosch P7100 fuel pump which was required for higher horsepower ratings and for the higher injection pressures needed to meet stricter emission legislation enacted 1 1 1994 The belief is that the vibrations and weight of the P7100 fuel pump cause the dowel pin to loosen in its bore and possibly fall out If the dowel pin does fall it can be caught in the fuel pump gear causing a major problem cracked cam nose or it can fall between the cam gear and the front housing and in its path to the bottom of the oil pan crack the gear case housing I ve heard many a story of how the cracked housing has been fixed using J B Weld epoxy Alternately the gear housing can be removed and replaced but this is a big task as the engine s camshaft has to be removed to remove replace the housing A final fall out scenario the pin falls to the bottom of the oil pan and resides in the bottom of the pan forever or at least until the pan is removed There is a screen on the oil pickup tube that prevents the pin from moving into anywhere other than the bottom of the oil pan The TST Solution Several methods of securing the pin into its bore have been developed by shops that service B series engines These methods have been covered in previous TDR magazines Issu
331. the Bosch P7100 fuel pump can affect performance Low rpm miss instability white smoke hard starting low power may be the result This bulletin gives the technician additional information to assist in diagnosis of the above problems CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS SUBJECT DESCRIPTION 18 11 96 96 BR Revised injection pump timing specifications 3 22 96 Arevision in the injection pump timing specification on Cummins engines with a CPL 2022 or 2023 should be utilized when checking or performing injection pump timing CATEGORY 19 STEERING TSB MODELS SUBJECT DESCRIPTION 19 01 96 95 96 BR Clunk or rattle felt in steering column wheel 2 9 96 The condition is a clunk or rattle in the steering wheel column during slow turns or stops on some 95 96 trucks Diagnosis includes a check of all fasteners for the appropriate torque value 19 05 96 94 96 BR Shimmy after striking a bump or pothole 8 30 96 4x4 trucks with sales This bulletin supersedes TSB 19 04 95 5 12 95 The bulletin discusses a sustaining vibration codes Z8A and Z8B shimmy felt in the front end of the vehicle after striking a bump or pothole The repair procedure and 4x2 cab chassis involves replacing the steering damper replacing the track bar if necessary and the addition of Z3B built before an auxiliary steering damper 5 15 96 38 A Publication of the TURBO DIESEL REGISTER CATEGORY 19 STEERING TSB MODELS SUBJECT DESCRIPTION 2
332. the correct transmission fluid consult your Owner s Manual Briefly the reason Dodge has the 3 and 4 designations is the highly refined base stock and friction modifiers that are specifically designed for the Chrysler transmission A footnote to the ATF fluid discussion Many owners are new to the Dodge product In order to check the ATF fluid level the transmission should be at operating temperature and the fluid checked on level ground with the transmission sector in neutral When in neutral the fluid is being routed through the transmission cooler unit If you check the fluid in park the level will show higher than it actually is as fluid is not being routed to the cooler in the park position If you make the mistake of checking the fluid level with the vehicle in park the transmission may be operating without sufficient fluid AXLE LUBRICANT The Owner s Manual suggests that the differential oil be changed every 30 50 thousand miles depending on the load factor The specification for the axle oil is straightforward use an API GL 5 rated oil Use the viscosity that is recommended in your manual This replacement fluid is easy to find at the local auto parts store However should your 89 02 truck with a Dana differential be a limited slip model you ll have to add Mopar s Hypoid Gear Oil Additive Friction Modifier to your fluid mixture Yes the lubricant is easy to find the friction modifier is not For the modifier
333. the introduction of the extended cab A Publication of the TURBO DIESEL REGISTER 1996 Turbo Diesel What is New Deleted tailgate top protector Deleted SLT tape stripe Added optional Camper suspension package Revised optional radio Revised alternator rating to 136 amps Revised RE electronic control of automatic transmission Models Available 2500HD as standard cab extended cab long bed cab chassis 4x2 and 4x4 3500 same as above No short bed models available Engine Ratings Increased for 1996 215 HP and 440 ft lbs for manual transmission 180 HP and 420 ft lbs for automatic transmission California engines were rated lower at 1995 specs At mid year 1996 California engines were required to have exhaust gas recirculation EGR Transmissions Five speed manual NV4500 5th overdrive Four speed automatic 47RE 4th overdrive with locking converter This is a new electronically controlled transmission Maximum Tow Ratings 2500 regular cab manual or automatic 3 54 axle 10 500 pounds 16 000 GCWR 2500 regular cab manual or automatic 4 10 axle 12 300 pounds 18 000 GCWR Derate trailer weight for 4x4 3 54 axle 500 pounds 4 10 axle 400 pounds Derate trailer weight for extended cab 0 3500 regular cab manual or automatic 3 54 axle 10 500 pounds 16 000 GCWR 3500 regular cab manual or automatic 4 10 axle 11 900 pounds 18 000 GCWR Derate trailer weight for 4x4 3 54 axle rat
334. the propeller shaft is replaced using the chart listing the appropriate part numbers 03 003 06 03 07 DR Axle fluid level 10 20 06 This bulletin supersedes TSB 03 001 04 revision A dated 5 11 04 The axle fill holes on some 2004 Dodge Truck axles may be located 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 Fluid Level measured from the bottom of the fill hole Fluid Capacity 10 5 Rear Axle 1 inch inch 85 oz SAE 75W 90 Synthetic 11 5 Rear Axle Y4 inch inch 122 oz SAE 75W 90 Synthetic 9 Front Axle inch inch 76 oz SAE 75W 90 Synthetic Note The limited slip feature on 2500 3500 series Ram Trucks utilizes the Trac Rite locking feature which does not require Trac Lok additives or friction modifiers 16 A Publication of the TURBO DIESEL REGISTER CATEGORY 6 CLUTCH TSB MODELS SUBJECT DESCRIPTION 06 001 03 03 BR Rat
335. the recommended oil filters for use with Cummins 5 9L diesel engine Part No Manufacturer 05016547AC Mopar LF3894 Fleetguard Stratapore LF3552 Fleetguard Microglass LF3959 Fleetguard Cellulose 3937695 Cummins Cellulose FL896 MotorCraft Cellulose L45335 Purolator Cellulose PF1070 AC Delco Cellulose The information only bulletin was issued to alert the field to problems caused by aftermarket oil filters For example neoprene compounds used internally in the manufacture of oil filters not recommended by DaimlerChrysler may separate from the filter lodge in the piston cooling nozzle and cause the engine to fail THIS IS NOT AN ENGINE DEFECT Engine Oil Pan Gasket Sealing 98 02 BR 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 Crankcase Breather Overflow 98 02 BR 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 tru
336. the scan tool may display Freeze Frame data incorrectly The PCM software must be updated to calibration level OlCall4A A Publication of the TURBO DIESEL REGISTER 63 TSBs Issued During 02 CATEGORY 2 FRONT SUSPENSION TSB MODELS SUBJECT DESCRIPTION 02 001 01 94 01 Rear of vehicle sits too high to allow hook up to a fifth wheel trailer 1 19 01 This bulletin applies to 2500 and 3500 4x4s The curb 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 01 Parking brake pedal adjustment 3 9 01 This bulletin applies to 2500 3500 series Ram trucks with four wheel disc brakes built before November 20 2000 Parking brake cable appears to be mis adjusted which may cause the parking brake lamp to remain illuminated even after the parking brake pedal has been released The parking brake system however is not mis adjusted and functions normally Install new parking brake cables CATEGORY 8 ELECTRICAL TSB MODELS SUBJECT DESCRIPTION 08 010 01 94 02 Airbag clock spring service 5 25 01 When servicing any airbag system it is essential to follow the proper Service Manual and or Diagnostic Manual procedures for diagnosing testing and replaci
337. the shipping cap has not been left on the end of the valve Inspect the charge air cooler hoses and clamps for proper installation Inspect all connections and clamps for looseness Verify that no leaks are present when the engine is under boost conditions e While performing the following road test verify that the turbo boost pressure is 16 psi during wide open throttle WOT acceleration e While road testing the vehicle in a safe area and manner conduct an acceleration test For vehicles equipped with an automatic transmission conduct a 0 60 mph acceleration test For vehicles equipped with a manual transmission conduct a 40 60 mph acceleration test in fourth gear It may take the technician performing several acceleration tests to obtain consistent acceleration times A performance vehicle tire size weight chart is provided A summary of the chart reveals 0 60 mph test for automatic trucks 13 5 to 15 secondsis acceptable In the 40 to 60 mph test for manual trucks in fourth gear can vary from 7 5 to 9 0 seconds Correction factors for vehicle weight and altitude are presented 18 24 99 00 BR 5 9L 24V diesel engine intermittent engine stumble 11 15 99 This information applies to vehicles equipped with a 5 9L 24V diesel engine built before engine serial number 56624822 with a date of manufacture of August 28 1999 This information is available on the engine data plate which is located on the left side of the engine affixed to the
338. the very expensive VP 44 injection pump A fuel pressure gauge for a 24 valve engine is mandatory As for the installation you will be dealing with fuel albeit less volatile diesel fuel Nonetheless you want to minimize the possibility of fuel leakage On the 98 5 and 99 trucks the filter is in a housing and the housing drops down from a horizontal filter bracket On top of the bracket are two ports that are tapped and plugged with a 1 8 NPT plug The innermost plug is the clean side of the filter Remove the innermost plug and install an electric Westach fuel pressure sending unit Because the Westach fuel pressure gauge does not always match other gauges that owners have installed the gauge can be mounted at the bottom of the kick panel in a rubber donut mounting kit This keeps the gauge hidden and unnoticed Because the Westach gauge is electric the chance of fuel leakage is minimized There are no fuel isolators to malfunction and therefore no fluid A Publication of the TURBO DIESEL REGISTER can leak into the cab The Westach gauge is also the least expensive and least prone to give the customer a problem Low cost and dependability an unbeatable combination For the 00 to 02 trucks the fuel filter assembly was changed to make fuel filter changes easier to perform To change the fuel filter one simply removes a plastic cap and the filter comes out of its housing For those wanting to install a fuel pressure gauge this pre
339. tifies 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 72 A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE Continued 18 025 02 03 DR Erroneous diagnostic trouble codes stored in the transfer case control module TCCM 9 4 02 This bulletin applies to 2003 4WD ram trucks equipped with an electric shift on the fly transfer case sales codes DH3 or DH5 built before November 1 2002 During a module scan or check of the TCCM the technician may see erroneous stored trouble codes The codes should be ignored 18 015 03 03 DR Powertrain control module PCM shift quality improvements 4 4 03 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 befo
340. tion is a customer pay procedure 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 module s motor If there is RFI the bulletin describes the installation of an RFI filter in series with the electric fuel pump 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 89 93 AD Use of two digit calendar year codes in automotive computers 94 99 BR There has been a great deal of recent media attention regarding the turn of the century year 2000 Y2K etc and the effect it will have on computers that have used two digit calendar year coding in their programming Questions are arising regarding computers used in automotive applications and the effect year 2000 will have on them Two digit calendar year codes have not been used in any Chrysler automotive onboard applications and no problems related to use of two digit co
341. tip once the filter is moved from its tool tight position to a hand tight removal place a large freezer bag around the filter Now when it drops from the housing extra fluid simply spills into the bag and not on the floor Additionally it is easy to retrieve the bag filter from around the air conditioning lines as you don t have to worry about tipping spilling oil EMERGENCY REPAIRS Emergency repair of small holes in a gas tank can be made by rubbing a bar of soap across the hole The leak will stop A permanent repair can be made using epoxy Emergency temporary repair of small radiator leaks can be made by putting in two or three egg whites Start the engine to circulate the coolant and get the egg to the hole Oatmeal or flour may also work An emergency repair for a hole punched in your oil pan is to round the hole with a punch then insert a rubber tire valve stem first into the hole Coat the valve with gasket cement if available Push or pound it home with a hammer IN THE TOOLBOX Plastic tie wraps are so handy almost everyone has them in the toolbox Keep them organized by hanging a bunch on a single tie then cut the head off the single tie Friction will keep them in place To get a new one just slide it off the end When cutting off old ties cut them near the back of the head so they can be used again for a smaller project Most tool kits contain both metric and standard wrenches Color code with paint or tape th
342. tle sound from transmission when idling 5 16 03 This bulletin applies to vehicles equipped with a 5 9L Cummins high output Turbo Diesel sales code ETH and NV5600 six speed manual transmission sales code DEE built on or before May 11 2003 The vehicle operator may describe a rattling sound when idling in neutral with the clutch pedal released The bulletin involves replacing the clutch disc with a revised part 06 001 07 07 Clutch system may over adjust causing difficulty engaging transmission gear 2 03 07 This bulletin involves replacement of the clutch system flywheel pressure plate and disc This bulletin applies to vehicles equipped with a 5 9 liter or 6 7 liter Cummins Turbo Diesel engine and the G56 manual transmission sales code ETH ETJ and DEG respectively and built on or before November 09 2006 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 08 004 03 02 03 DR Electro mechanical instrument cluster MIC erroneous indicator lamps 3 14 03 Three conditions have been identified which may b
343. to overcome the pre hold position On 06 and 07 DR vehicles the circuits fed by the IOD fuse are Radio EVIC Wireless Control Module Hands Free Module Satellite Radio Video Screen CCN wake up with ignition off Underhood Lamp and CCN Interior Lighting 08 020 06 06 DR Overhead console average fuel economy display 5 5 06 This information only bulletin discusses the calculation method used by the truck s average fuel economy display On 06 vehicles the calculation has been changed to use the last displayed average fuel economy as a starting point for the calculation after a reset The average fuel economy will then be adjusted from that point If the display read 21 6 mpg at the time the reset was activated the new display will start at 21 6 mpg and would change from that point depending on the current fuel usage This was done to eliminate the extreme variations caused by very high or low fuel usage at the time of the reset 08 021 06 06 TIPM Flash DTC s indicating short circuits in the wiring on the trailer or no engine crank with DTC Rev A P1277 starter control circuit too low 10 13 06 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 cod
344. to purchase a spare Be ready for the inevitable A Publication of the TURBO DIESEL REGISTER 03 04 5 Fuel Transfer Pump Installation Following the well written instructions that were in the Fel e Back up top Disconnect the electrical connector from Pro M4089602 box the installation went on and off without the fuel transfer pump the pinch to release is on the a hitch The following is a combination of the instruction bottom of the connector sheet directive and some common sense tips e Push the cables and wiring to the side of the fuel filter to make the transfer pump easier to access e Crawl underneath the truck and slip a heater hose 5 8 inside diameter over the existing fuel filter drain hose e Open the fuel drain valve at the fuel filter housing Drain the fuel and close the drain valve Unplug the water in fuel sensor Note how the wires and cables have been pushed to the side of the fuel filter e Remove the four 5mm hex head bolts that hold the transfer pump to the filter housing Extend the fuel filter drain hose to save the aggravation of having s Remove the transfer pump and confirm that the sealing the fuel drain onto the frame which is caused by the existing short O ring is also removed from the filter housing drain hose e Back under the truck Locate the junction of the truck s hard fuel line to rubber fuel line Pinch the tabs of the quick disconnect fitting and remove the fuel line
345. tor 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 04 DR Binding front power window 8 2 04 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 03 04 DR Improved secondary door seal 1 31 05 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 05 06 DR Low gloss interior trim 4 2 05 This information only bulletin discusses that all Chrysler Dodge and Jeep vehicles are designed with a low gloss interior trim This low gloss finish maintains pleasing aesthetics and minimizes glare of the instrument panel into the windshield This low gloss finish should not be altered with a medium or high gloss interior treatment solution such as MOPAR Protector s or other Armor All like products Instead MOPAR Satin Select part number 05174395AA which has been specifically developed to remove minor surface contamination an
346. uel Air Separation System or FASS introduced a mid price fuel transfer pump option for the 98 5 02 owner The product is called the Dodge direct replacement pump DDRP and it sells for 285 Advertised as a direct replacement the installation should be simple To test out that belief the following is a pictorial showing how we installed the DDRP MORE LATER A Publication of the TURBO DIESEL REGISTER 121 122 FROM ISSUE 60 HOW DO YOU CHANGE THE FUEL FILTER If you are an experienced diesel owner feel free to skip this article But be forewarned the convention of the TDR is to add information to an article that will make it worth reading for the seasoned professional Let s see what can be added to this simple project to validate the worth of your TDR subscription FUEL FILTER BASICS You can browse through your Dodge Owner s Manual you can preach the virtues of maintenance to your friends and your offspring but nothing makes a lasting impression like practicing what you preach Maybe should rephrase this to read that nothing makes a lasting impression like not practicing what you preach Admittedly I ll end up replacing an entire assembly because of my lack of maintenance to a component part of the assembly Just like running out of fuel when you re the driver it s my fault and end up taking the long costly road to correcting the situation The most delicate part of a diesel engine is the fuel injection s
347. ule SEBC Replacement of the SEBC is covered in the repair procedure Lack of power poor acceleration in cold ambient temperatures Below 33 F some vehicles may be slow to accelerate or feel low on power The condition may be caused by ice forming at the fuel intake area of the fuel gauge sending unit module A revised module part number and repair procedure are outlined Erratic 3 4 or 4 3 shifter Note See TSB 18 06 93 A Poor performance lack of power Note See TSB 18 05 93 Engine rpm fluctuates when 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 29 CATEGORY 19 STEERING TSB 19 02 05 B 11 3 95 19 01 94 1 28 94 19 04 94 6 3 94 19 03 93 4 16 93 19 02 91 4 22 91 MODELS 94
348. um 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 28 A Publication of the TURBO DIESEL REGISTER CATEGORY 18 VEHICLE PERFORMANCE TSB MODELS 18 29 95 A 94 95 BR with 10 16 95 automatic transmission 18 01 94 94 BR with 1 14 94 automatic transmission 18 10 94 A 94 BR 7 29 94 18 05 93 91 93 AD 4 30 93 18 06 92 A 91 93 AD with 7 23 93 automatic transmission 18 05 92 92 AD 6 15 92 18 06 92 91 92 AD 6 29 92 18 10 92 A 91 92 AD with 9 8 92 automatic transmission 18 11 92 91 92 AD 7 13 92 18 17 92 91 AD 9 8 92 18 18 92 91 92 AD 10 19 92 18 15 92 91 AD A Publication of the TURBO DIESEL REGISTER SUBJECT DESCRIPTION Diesel low power performance specs The bulletin applies to automatic transmission trucks with a customer complaint of slow acceleration or low power Performance tests 0 60 are performed and an acceleration table to reference is provided The bulletin guides the dealership through a series of trouble shooting tests to troubleshoot the low power complaint Checks for wide open throttle a low pressure fuel system check and finally an injection pump timing adjustment are described Lack of power harsh transmission shifts
349. ummins 5 9 liter engine The 2007 5 consumer pickup models 2500 and 3500 received the Cummins 6 7 liter engine rated at 350 HP and 650 ft lbs torque with the automatic transmission 350HP and 610 ft lbs torque with the manual transmission 305 HP and 610 ft lbs for commercial Chassis Cab 3500 models using the Cummins 6 7 liter engine The 4500 and 5500 trucks are introduced with the same engine and engine ratings as the 3500 Chassis Cab Transmissions For early 2007 the consumer pickup models 2500 and 3500 used the existing G56 six speed manual transmission and 48RE four speed manual transmission With the mid year 2007 5 introduction of the 6 7 liter engine the automatic transmission was revised to a Chrysler supplied 68RFE six speed unit 48 RE Versus 68RFE Gear Ratio Comparison 1 2 3 4 5 6 03 5 07 48RE 2 45 1 45 1 0 69 07 5 newer 68RFE 3 23 1 84 1 41 1 00 82 63 With the mid year 2007 5 introduction of the 6 7 liter engine the manual transmission the Mercedes Benz designed G56 six speed unit was revised In order to raise the overall gear ratios in the manual transmission the redesign dropped a tooth on the input shaft The resulting gear ratios are as follow G56 Versus G56R Gear Ratio Comparison 1 2 3 4 5 6 05 07 G56 6 26 3 48 2 10 1 38 1 00 79 07 5 newer G56R 5 94 3 28 1 98 1 31 1 00 74 Commercial Cab Chassis no changes from 2006 G56R six speed manual transmission and Aisin AS68RC six spe
350. unt 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 94 99 BR Squeaking noise from rear leaf springs 09 10 99 This bulletin supersedes TSB 02 03 96 dated may 31 1996 If the diagnosed condition is a squeaking noise coming from the rear of the vehicle the bulletin gives the correct repair procedure to replace the leaf spring tip liners install spring clip isolators CATEGORY 5 BRAKES TSB MODELS SUBJECT DESCRIPTION 05 04 99 98 99 BR Chassis dynamics diagnosis 05 28 99 This 21 page bulletin involves diagnosis and repair of a vehicle drift condition and on some vehicles installing a shim between the wheel and the brake rotor between the wheel and hub bearing assembly or between the wheel and hub extension Chassis dynamics diagnosis is the diagnosis of a condition where the vehicle may move either to the right or the left when not controlled by the driver This condition can be caused by any of the following Non factory installed options e g snow plow ti
351. ur columnist who was assigned this daunting task went with the information provided by Dodge s data books which are written at the beginning of a model year and do not reflect later running production changes Warranty began in 1994 with a basic one year 12 000 mile warranty on the entire truck and 5 year 70 000 mile powertrain warranty The separate truck powertrain warranties were consolidated and currently the package is 3 years 36 000 miles on the entire truck including powertrain Engine warranty has stayed constant at 5 years 100 000 miles Tow Ratings have changed considerably from year to year and from option model to option model and even within option models so read carefully if you are interested in or seeking such information Some models were are rated to tow much less weight than others Watch out for lightweights A Publication of the TURBO DIESEL REGISTER PROBLEM AREAS Please keep in mind that there is no such thing as the perfect truck or car All vehicles will contain certain designs systems or parts that are more prone to failure than might normally be expected Looking at these negatives the image of the vehicle can be tarnished However to look on the positive side the owner is aware of the problems and can take corrective action and make informed decisions With these thoughts in mind the following are common problem areas on the subject trucks Common Problem areas 1994 1998 5 Included
352. ve the filter from its crowded location will note however if your engine is hot you may need to work fast or the filter could melt through the bag Justin Kirchhoft A Publication of the TURBO DIESEL REGISTER Another method is to drain the filter first by punching a small hole in its bottom before removing it Dave Lewis and James Johnson 14 FUEL In model years 94 through 98 the engines are equipped with a plunger type fuel transfer pump with a button type primer It is hard to locate and see the plunger button to prime the fuel system Paint the end of the plunger with a bit of white paint for greater visibility Jim Anderson With the introduction of the Second Generation trucks in 94 many members adapted to the decreased clearance problems in removing and replacing the fuel filter by using a filter strap wrench with a socket extension to remove the old fuel filter The procedure is to disconnect the water sensor wire thread the strap wrench under the wire and the drain tube onto the filter near the top tighten the wrench strapping and loosen the filter It is then spun off and removed by hand Prime the new filter with clean fuel before installing it TDR member Earl Kenney cautions us about diesel fuel storage Fuel stored in cans can collect water that may produce gels Fuel stored for long periods in cans coated with galvanizing or zinc will liberate a chemical from the coating that can form harmful compounds resu
353. ve the fuel shutdown arm This also makes a fine theft deterrent for the vehicle Adjustments and replacements are do it yourself operations Ref 46 p 32 adjust Re start run solenoid 41 p 38 48 p 98 Glitch Manual transmissions fluid specials Fix The five speed and six speed New Venture Gear NV series manual transmissions both specify a lubricant that is not available at retail locations in quart quantities Suitable substitutes have been discovered by TDR members that include 80W 90 synthetic GL 4 gear oil from Amsoil and Red Line for five speed transmissions and Pennzoil synthetic 75W 90 gear oil for six speed manual transmissions at much lower cost than the Mopar lubricant from the Dodge dealer Use of the wrong lube in either transmission will result in poor shifting and increased wear Ref 37 p 104 Glitch The dreaded dowel pin drop Fix A potential problem for 94 98 12 valve trucks and some 99 trucks is the dowel pin used to locate the aluminum timing gear cover on the front of the engine When this cheap part falls out expensive things happen and it s shown some proclivity for falling out Cummins says the number of problem engines has been very small but has revised the A Publication of the TURBO DIESEL REGISTER part There are a number of preventative measures some of which can be done with hand tools When replacing the dowel pin replace the crankshaft oil seal and vice versa due to
354. wer steering or automatic transmission fluid is to be used in these systems Damage may result to the power steering pump and system if the incorrect fluid is used Do not overfill the power steering reservoir If the air is not purged from the power steering system correctly pump failure could result CATEGORY 21 TRANSMISSION TSB MODELS SUBJECT DESCRIPTION 21 023 05 06 Out of park sense alarm 11 11 05 This information only bulletin applies to vehicles equipped with a 5 9L Turbo Diesel engine sales code ETH This information only bulletin discusses an alarm for out of park transmission setting Vehicles with a diesel engine and an automatic transmission are equipped with an alarm that warns the customer upon exiting the vehicle that the transmission is not in the Park position This feauture will only be functional under the following conditions engine running e foot off the brake pedal e driver s seat belt is unbuckled e driver s door is 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 21 006 06 05 06 Transmission jumps out of reverse 3 11 06 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 conditio
355. 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 cont
356. x cross member contacting the vehicle s frame as the vehicle is operated over a rough surfaced road The repair involves installing isolators on two cargo box cross member rails 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 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 A Publication of the TURBO DIESEL REGISTER CATEGORY 24 AIR CONDITIONING TSB MODELS SUBJECT DESCRIPTION 24 11 97 94 98 BR A C evaporator odor 7 11 97 This bulletin supersedes technical service bulletin 24 06 95A dated 5 26 95 Some vehicle operators may experience a 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
357. xle 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 ho
358. xplain why the maximum boost specification is important to an owner searched the archives for an easy to understand article on turbocharger boost The following is a quick review of turbocharger basics TURBO BASICS The principle behind a turbocharger is simple get more power from the engine without increasing the engine s size To increase engine power you start by adding more and more fuel But soon you d be wasting fuel because the fuel needs air to burn Technically it needs the oxygen in the air to burn In a naturally aspirated engine the air is pulled from the atmospheric pressure surrounding the engine into the combustion chamber on the intake stroke of the cycle At sea level there are 016 pounds of oxygen per cubic foot At higher altitudes air is thinner and there s less oxygen For example at 5 000 feet there s only 010 pounds of oxygen per cubic foot So at higher altitudes there s a greater demand for air to supply an engine with oxygen A turbocharger is the solution In the simplest of analogies think of a turbocharger as two pinwheels connected back to back via a common shaft As you blow on one wheel the other wheel turns too Inside a turbocharger exhaust gases flow out of the combustion chambers into the turbine housing The exhaust gas is channeled to the pin wheel causing the pin wheel turbine to rotate The turbine wheel turns a common shaft which is connected to a pin w
359. y radio equipment 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 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 A Publication of the TURBO DIESEL REGISTER CATEGORY 8 ELECTRICAL Continued 08 016 06 06 07 DR Intermittent operation of electrical components due to ignition off draw IOD fuse not being fully Rev A seated 7 18 06 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
360. ystem Because of the extremely close tolerances the fuel injection system cannot tolerate contamination Contamination can cause damage and at a minimum erratic performance The majority of low mileage fuel injection pump failures seen by Cummins warranty research department are caused by trash in the fuel system Considering that trash is not a defect in material and workmanship the resulting repair can be an expensive lesson in fuel system maintenance Replace the assembly or perform maintenance on a component part the choice is yours In this issue our back to the basics article will show you how to change a fuel filter on a 2007 5 to current model year engine On a one to ten scale this maintenance procedure ranks about a two in difficulty However fuel filter maintenance is often overlooked as new to diesel owners don t realize that fuel filter maintenance is called for every 15 000 miles After all when was the last time you changed your gasoline powered vehicle s fuel filter Why only 15 000 miles between fuel filter changes with a diesel The obvious answer diesel fuel is less refined than gasoline and is more susceptible to contamination by water and microbial activity Additionally to the diesel novice the job of changing a fuel filler can be intimidating Influenced by diesel folklore the novice is concerned that the injectors and or fuel system will have to be bled of trapped air a task that he does not know

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