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1. 32 33 Tighten the upper cooler bracket to cylinder block mounting bolt to 18 ft lbs 24 N m Tighten the lower cooler bracket to transmission adapter mounting bolt to 18 ft lbs 24 N m Connect the coolant inlet and outlet hoses to the transmission cooler Make sure that the hose clamps are installed inboard of the upset bead Connect the transmission cooler outlet line to the transmission cooler Tighten the fitting to 280 in lbs 32 N m Connect the wiring harness clip to the cooler bracket Install the left front inner fender shield Install the left front wheel and tire assembly Tighten the lug nuts to 135 ft lbs 180 N m Raise the vehicle fully Connect the new transmission cooler line to the transmission cooler Figure 4 Hand start the fitting but do not tighten Connect the transmission cooler line to the transmission Figure 4 Hand start the fitting but do not tighten Check the alignment of the new cooler line Figure 6 Make sure that the hose portion of the line is not contorted or twisted as this can cause the hose to fail Keeping the cooler line aligned properly tighten the cooler line to transmission fitting to 280 in lbs 32 N m Keeping the cooler line aligned properly tighten the cooler line to cooler fitting to 280 in Ibs 32 N m Check the alignment of the new cooler line Make sure that the hose portion of the line is not contorted or twisted If the hose po2. plus applicable Distributor Dealer allowance to your claim Distributor Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles The Vehicle List is arranged by Distributor Dealer code and in Vehicle Identification Number VIN sequence The lists are for Distributor Dealer reference in arranging for service of involved vehicles Customer Satisfaction Notification No C44 16 Transmission Cooler Line Vehicle Lists Global Recall System VIP and Distributor Dealer Follow Up All involved vehicles have been entered into the Global Recall System GRS and Vehicle Information Plus VIP for Distributor Dealer inquiry as needed GRS provides involved Distributors Dealers with an updated VIN list of their incomplete vehicles Completed vehicles are removed from GRS within several days of repair claim submission Distributors Dealers must perform this repair on all unsold vehicles before retail delivery Distributors Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor Dealer Owners are requested to schedule appointments for this service A sample copy of the owner notification letter is attached Additional Information If you have any questions or need assistance in completing this actio
3. DAIMLERCHRYSLER February 2004 Distributor Dealer Service Instructions for Customer Satisfaction Notification No C44 Transmission Cooler Line 2003 2004 DR Dodge Ram Pick Up Trucks NOTE This notification applies only to the above vehicles equipped with a 5 9L Cummins diesel engine Sales Code ETC or ETH and an automatic transmission Sales Code DG8 or DGP built through November 24 2003 MDH 112407 IMPORTANT Some of the involved vehicles may be in Distributor Dealer vehicle inventory Distributors Dealers should complete this repair on these vehicles before retail delivery Distributors Dealers should also perform this repair on vehicles in for service Involved vehicles can be determined by using the VIP inquiry process The transmission cooler line on about 97 000 of the above vehicles 233 in Int markets can transmit high pressure pulses when the vehicle is operated at heavy loads These pulses may cause the engine mounted transmission cooler to crack and leak fluid which could result in significant transmission damage Repair The transmission cooler line must be replaced on all involved vehicles In addition the engine mounted transmission cooler must be inspected and replaced if necessary Copyright 2004 DaimlerChrysler Corporation All Rights Reserved Customer Satisfaction Notification No C44 2 Transmission Cooler Line Parts Information A Transmission Cooler Line Part Number Des
4. TURN LINE 4 COOLER LINE 7 Keeping the cooler line aligned properly tighten the cooler line to transmission fitting to 280 in lbs 32 N m 8 Keeping the cooler line aligned properly tighten the cooler line to cooler fitting to 280 in Ibs 32 N m Customer Satisfaction Notification No C44 7 Transmission Cooler Line 9 Check the alignment of the new cooler line Make sure that the hose portion of the line is not contorted or twisted If the hose portion is twisted or contorted loosen both cooler line fittings and repeat Steps 6 8 10 Lower the vehicle start the engine and ensure that there are no cooler line leaks 11 Check the transmission fluid level and adjust if necessary 12 Return the vehicle to the customer Customer Satisfaction Notification No C44 8 Transmission Cooler Line C Replace Engine Mounted Transmission Cooler and Cooler Line NOTE The following procedure is only required if the engine mounted transmission cooler requires replacement per the inspection in Section A Very few vehicles are expected to require transmission cooler replacement 1 Disconnect the negative battery cable from each battery 2 Open the radiator drain plug and drain the coolant from the radiator into an appropriate container Save the coolant for later re use WARNING Do not loosen the radiator drain plug with the system hot and under pressure Serious burns from coo
5. cription CBLAC441 Transmission Cooler Line Each Distributor Dealer to whom vehicles in the notification were invoiced will receive enough transmission cooler lines to service about 10 of those vehicles B Transmission Cooler Part Number Description CBLAC442 Transmission Cooler Engine Mounted Due to the small number of involved vehicles expected to require transmission cooler replacement no parts will be distributed initially Transmission coolers should be ordered only after inspection determines that replacement is required Very few vehicles are expected to require transmission cooler replacement Customer Satisfaction Notification No C44 3 Transmission Cooler Line Service Procedure A Inspect Transmission Duty Cycle NOTE Only vehicles with high duty cycle operation as determined by the inspection below require transmission cooler replacement Very few vehicles are expected to require transmission cooler replacement 1 Connect the DRB III to the data link connector located under the instrument panel Turn the ignition key to the ON position 2 Select 1 DRB II Standalone from Main Menu screen 3 Select 1 1998 2004 Diagnostics from Standalone Main Menu screen aN Select 1 All Except Below from 1998 2004 Diagnostics screen Select 1 Engine from Select System screen Select 1 Diesel from Engine Controller Type scr
6. een YI vn wm Press ENTER two 2 times to continue 8 Select 2 Duty Cycle Monitor 9 Record the duty cycle value for the 91 100 range 10 Press PAGE BACK to exit and then disconnect the DRB III 11 gt If the 91 100 duty cycle value is GREATER THAN 3 5 the engine mounted transmission cooler must be replaced Continue with Section C Replace Engine Mounted Transmission Cooler and Cooler Line B gt If the 91 100 duty cycle value is 3 5 OR LESS the transmission cooler does NOT require replacement Only the cooler line requires replacement Customer Satisfaction Notification No C44 4 Transmission Cooler Line 12 13 14 15 Inspect the engine coolant for indications of contamination with transmission fluid If the coolant is contaminated the transmission cooler must be replaced and the coolant system must be flushed Continue with Section C Replace Engine Mounted Transmission Cooler and Cooler Line Inspect the transmission fluid for indications of contamination with engine coolant If the transmission fluid is contaminated the transmission cooler must be replaced and the transmission must be rebuilt or replaced Continue with Section C Replace Engine Mounted Transmission Cooler and Cooler Line Inspect the engine mounted transmission cooler for signs of external fluid leakage If the cooler shows signs of leakage the engine mounted transmission cooler must be r
7. eplaced Continue with Section C Replace Engine Mounted Transmission Cooler and Cooler Line If the engine coolant and transmission fluid were NOT contaminated and there are no external cooler leaks continue with Section B Replace Transmission Cooler Line Customer Satisfaction Notification No C44 5 Transmission Cooler Line B Replace Transmission Cooler Line L 2 Raise the vehicle on an appropriate hoist Disconnect the transmission cooler line from the transmission Figure 1 Disconnect the transmission cooler line from the engine mounted transmission cooler Figure 1 Connect the new transmission cooler line to the engine mounted transmission cooler Figure 1 Hand start the fitting but do not tighten Connect the transmission line to the transmission Figure 1 Hand start the fitting but do not tighten FIGURE 1 1 ENGINE MOUNTED TRANSMISSION COOLER 2 REMOVE COOLER LINE FROM TRANSMISSION AND COOLER 3 COOLER LINE Customer Satisfaction Notification No C44 6 Transmission Cooler Line 6 Check the alignment of the new cooler line Figure 2 Make sure that the hose portion of the line is not contorted or twisted as this can cause the hose to fail FIGURE 2 1 ENGINE MOUNTED TRANSMISSION COOLER 2 ENSURE THAT THE HOSE SECTION OF THE COOLER LINE IS NOT CONTORTED OR TWISTED AND THAT IT REMAINS PARALLEL WITH THE RETURN LINE 3 RE
8. lant can occur 3 If the engine coolant is contaminated with transmission fluid the cooling system must be flushed to remove the contamination Follow the procedure in Section 7 Cooling in the 2004 DR Service Manual to flush the cooling system 4 Raise the vehicle on an appropriate hoist 5 Remove the three 3 starter mounting bolts Figure 3 6 Move the starter forward far enough to clear the bell housing then tilt the nose of the starter downwards and lower the starter enough to remove the nuts that secure the wiring harness to the starter Remove the starter from the engine and set it aside Customer Satisfaction Notification No C44 9 Transmission Cooler Line FIGURE 3 1 MOUNTING BOLTS 2 STARTER 3 ADAPTER IF EQUIPPED 7 Disconnect the transmission cooler line from the transmission Figure 4 8 If the transmission fluid is contaminated with engine coolant the rest of the cooler system must be flushed and the transmission must be rebuilt or replaced Follow the procedure in Section 21 Transmission in the 2004 DR Service Manual and Warranty Rebuild Replace policies to repair the transmission if the fluid is contaminated IMPORTANT When rebuilding the transmission all friction material rubber based seals and the torque converter must be replaced In addition the transmission cooler lines and radiator mounted cooler must be flushed 9 Lower the vehicle to a working le
9. n please contact your International Service and Parts manager International Service and Parts DaimlerChrysler Corporation DAIMLERCHRYSLER CUSTOMER SATISFACTION NOTIFICATION TRANSMISSION COOLER LINE Dear Ram Diesel Truck Owner The satisfaction of our customers is very important to DaimlerChrysler Because of this we are requesting owners of some 2003 and 2004 model year Dodge Ram Pick up trucks equipped with a 5 9L Cummins diesel engine and an automatic transmission to contact their dealer to have the following service performed The problem is The transmission cooler line on your truck can transmit high pressure pulses when the vehicle is operated at heavy loads These pulses may cause the engine mounted cooler to crack and leak fluid which could result in significant transmission damage What DaimlerChrysler DaimlerChrysler will repair your vehicle free of charge parts and and your dealer will labor To do this your dealer will replace the transmission cooler line do The engine mounted transmission cooler will also be inspected and replaced if necessary Cooler line replacement will take about one hour to complete Cooler replacement if required will take another two hours However additional time may be necessary depending on how dealer appointments are scheduled and processed What you must do Simply contact your dealer right away to schedule a service appointment Ask the dealer to hold the part for your
10. r payments Use one of the following labor operation numbers and time allowances Labor Operation Time Number Allowance Check transmission duty cycle and replace cooler line 21 C4 41 82 0 6 hours Check transmission duty cycle and replace cooler line and cooler assembly 21 C4 41 83 2 4 hours Check transmission duty cycle replace cooler line and cooler assembly and flush cooling system 21 C4 41 84 2 7 hours Check transmission duty cycle replace cooler line and cooler assembly and rebuild transmission 21 C4 41 85 10 9 hours Check transmission duty cycle replace cooler line and cooler assembly rebuild transmission and flush cooling system 21 C4 41 86 11 2 hours Check transmission duty cycle replace cooler line and cooler assembly and replace transmission includes diagnostic teardown 21 C4 41 87 6 0 hours Check transmission duty cycle replace cooler line and cooler assembly replace transmission and flush cooling system includes diagnostic teardown 21 C4 41 88 6 3 hours Customer Satisfaction Notification No C44 15 Transmission Cooler Line Completion Reporting and Reimbursement Continued Related Operations only for use with labor operations that include transmission repair or replace Skid Plate Equipped 21 00 02 60 0 2 hours Two Piece Propeller Shaft Equipped 21 00 02 62 0 2 hours 4x4 Equipped 21 00 02 66 0 8 hours Add the cost of the parts package s
11. rtion is twisted or contorted loosen both cooler line fittings and repeat Steps 29 31 Position the starter onto the engine Customer Satisfaction Notification No C44 13 Transmission Cooler Line 34 39 36 Il 38 39 40 T FIGURE 6 1 ENGINE MOUNTED TRANSMISSION COOLER 2 ENSURE THAT THE HOSE SECTION OF THE COOLER LINE IS NOT CONTORTED OR TWISTED AND THAT IT REMAINS PARALLEL WITH THE RETURN LINE 3 RETURN LINE 4 COOLER LINE Install the starter wiring Tighten the large battery cable nut to 120 in lbs 14 N m Tighten the smaller starter solenoid nut to 55 in lbs 6 N m Position the starter into the bell housing Figure 3 Install the three 3 starter mounting bolts and then tighten the bolts to 32 ft lbs 43 N m Lower the vehicle Connect both negative battery cables Fill the engine cooling system with coolant Re use the original coolant if it was not contaminated Start the engine and check for any leaks Check the transmission fluid level and adjust if necessary Customer Satisfaction Notification No C44 14 Transmission Cooler Line Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System or on the Distributor DealerCONNECT Claim Entry Screen located on the Service tab Claims submitted will be used by DaimlerChrysler to record service completions and provide Distributor Deale
12. vehicle or to order it before your appointment If you need help If you have trouble getting your vehicle serviced please contact the DaimlerChrysler Distributor nearest your location A representative will assist you in getting your vehicle serviced This information can be found in the Customer Assistance section of your Owner s Manual If you have already experienced the problem described above and have paid to have it repaired contact the DaimlerChrysler Distributor nearest your location for reimbursement procedures We apologize for any inconvenience but we believe that this service will help to ensure your continuing satisfaction with your vehicle Thank you for your attention to this important matter International Service and Parts DaimlerChrysler Corporation C44 Buckle up for Safety Copyright 2004 DaimlerChrysler Corporation All Rights Reserved
13. vel 10 Remove the left front wheel and tire assembly 11 Remove the left front wheel well inner fender shield Customer Satisfaction Notification No C44 Transmission Cooler Line FIGURE 4 1 ENGINE MOUNTED TRANSMISSION COOLER 2 REMOVE COOLER LINE FROM TRANSMISSION AND COOLER 3 COOLER LINE 12 Disconnect the transmission cooler line from the engine mounted transmission cooler Figure 4 13 Disconnect the transmission cooler outlet line from the engine mounted transmission cooler Figure 4 10 Customer Satisfaction Notification No C44 ll Transmission Cooler Line 14 Disconnect the coolant inlet and outlet hoses from the engine mounted transmission cooler Figure 5 FIGURE 5 1 COOLER BRACKET MOUNTING BOLT LOCATIONS 2 ENGINE MOUNTED TRANSMISSION COOLER 3 COOLANT HOSES 15 Remove the wiring harness clip from the cooler bracket 16 Remove the three 3 transmission cooler bracket fasteners Figure 5 and then remove the cooler and bracket from the engine as an assembly 17 Install the new transmission cooler and bracket assembly Figure 5 Hand start the three 3 mounting fasteners only 18 Tighten the lower cooler bracket to cylinder block mounting bolt to 57 ft lbs 77 N m Customer Satisfaction Notification No C44 12 Transmission Cooler Line 19 20 pA 22 23 24 25 26 2l 28 29 30 31
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