TECHNICAL SERVICE BULLETIN

Reference Number(s): 02-003-02, Date of Issue: June 17, 2002
DODGE: BR/BE Ram Truck
GROUP: Front Suspension

OVERVIEW

This bulletin involves an update to the toe in specification for front end alignments.

DISCUSSION

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 performance and should be used whenever a front end alignment is performed.

POLICY

Information Only

TECHNICAL SERVICE BULLETIN

Reference Number(s): 03-001-02, Date of Issue: February 11, 2002
DODGE: 2002 (BE/BR) Ram Truck
GROUP: Front Axle

DESCRIPTION

Front Axle Disconnect System
This bulletin involves a mid-2002 model year deletion of the front axle disconnect system on 2002 (BE/BR)
2500 and 3500 Ram Trucks. This change effects the front axle, transfer case and engine/headlamp and dash
wiring harnesses.

BULLETIN CONTENT

This bulletin involves a mid-2002 model year deletion of the front axle disconnect system on the 2002 (BE/BR) 2500 and 3500 Ram Trucks. This change effects the front axle, transfer case, and engine, headlamp and dash wiring harnesses.

MODELS

2002 (BE/BR) Ram truck

NOTE: THIS BULLETIN APPLIES TO 2500 AND 3500 (BE/BR) RAM TRUCKSBUILT AFTER JANURARY 4, 2002 AND EQUIPPED WITH FRONT AXLES WITH THE FOLLOWING PART NUMBERS: 52070136AO, 52070137AO, 52070138AP, AND 52070139A0.

DISCUSSION:

1. The vehicles involved will retain Shift On the Fly (SFO) capability, however with this change, the front driveshaft will now turn continously when the vehicle is being driven.
2. When the vehicles is stopped in 2WD the front driveshaft will no longer spin freely.
3. The 4WD indicator light on the instrument panel is now controlled by a switch on the transfer case.
4. If there is a mechanical problem causing loss of 4WD the indicator light will be "ON" if the shifter is in the "4WD HI" or "4WD LO" position.
5. If the indicator light is not function properly when the transfer case shifter is in the 4WD position, the transfer case switch, dashboard indicator light or circuit should be diagnosed first.
6. Parts required for service on vehicles with this change are readily available already identified in the Mopar Part Catalog.

NOTE: DUE TO THE TIMING OF THIS INFORMATION IS NOT REFLECTED IN THE SERVICE MANUAL (PUBLICATION #81-370-02057).

NOTE: DIAGNOSTIC AND SERVICE PROCEDURES FOR THE FRONT AXLE DISCONNECT SYSTEM, RELATED VACUUM LINES, THE TRANSFER CASE SYNCHRONIZER ASSEMBLY, MAIN SHAFT ASSEMBLY, HUB, STRUTS, RETAINING RING, SLIDING CLUTCH AND SPRING SHOULD BE DISREGARDED. SERVICE INFORMATION TO THE SUPPORT THIS CHANGE IS CURRENTLY BEING DEVELOPED AND WILL BE ON A FUTURE MDS2 CD RELEASE WHEN DEVELOPMENT IS COMPLETE.

POLICY

Information Only.

Models: 1998-2002 (BR) Ram Truck

NOTE: THIS BULLETIN APPLIES TO 1998 - 2002 (BR) RAM TRUCKS EQUIPPED WITH THE 24-VALVE CUMMINS DIESEL ENGINE BUILT AFTER MARCH 27, 1998 (ESN 56443872).

Symptom/Condition:
Owners of 1998 - 2002 (BR) Ram Trucks equipped with the 24-valve Cummins diesel engine may experience engine oil overflow from the front crankcase breather when the vehicle is operated off-road on an extreme downhill grade (37.5% or 22° slope/grade). Operation of this type for extended periods of time can cause enough engine oil depletion to damage the engine. A kit containing all components necessary to eliminate the oil overflow has been made available. If the condition exists, perform the repair.

Parts Required:

Repair Procedure:

NOTE: REFER TO THE SERVICE MANUAL THAT 1S SPECIFIC TO THE VEHICLE ON WHICH YOU ARE WORKING. (REFERENCES IN THE PROCEDURE BELOW ARE TO SECTIONS WITHIN THE 2000 (BR) RAM TRUCK SERVICE MANUAL (PUBLICATION # 81-370-0008).

1. Open the hood.

NOTE: IN THE INTEREST OF CUSTOMER SATISFACTION, RECORD SET RADIO STATIONS AND REPROGRAM WHEN PROCEDURE IS COMPLETED.

2. Disconnect both negative battery cables.

3. Remove the air intake connector.

4. Remove the charge air cooler duct.

5. Remove the washer bottle.

6. Remove the fan shroud and viscous fan. (Section 7).

7. Remove the crankcase breather assembly and discard.

8. Remove the fuel filter/water separator assembly. (Section 14).

9. Remove the Bosch VP44 fuel injection pump, (Section 14).

10. Remove the CM551 engine control module.

11. Remove the mounting bolt that secures the fuel line to the tappet cover.

12. Disconnect and remove the fuel line "T" fitting and mounting bracket.

13. Remove the tappet cover mounting bolts and side cover.

14. Install new tappet cover with breather tube. Torque bolts to 24 N-m (17 ft. lbs.).

NOTE: BREATHER TUBE SHOULD BE ROUTED DOWN, BEHIND THE STARTER AND AWAY FROM THE DIFFERENTIAL.

15. Reconnect and install fuel line "T" fitting and mounting bracket.

16. Install the mounting bell that secures the fuel line to the tappet cover.

17. Install the engine controller.

18. Install the fuel pump. (Section 14).

19. Install the fuel filter/water separator assembly. (Section 14).

20. Install the replacement access plug on the front of the gear cover.

21. Install the fan shroud and viscous fan. (Section 7).

22. Install the washer bottle.

23. Install the charge air cooler duct.

24. Install the air intake connector.

25. Reconnect both negative battery cables.

26. Start the engine and check for leaks.

27. Close the hood and reprogram the radio (if necessary).

Policy: Reimbursable within the provisions of the warranty.

Time Allowance:
Labor Operation No: 09-85-05-91. Install New Breather Kit ....................3.2 Hrs.

Failure Code: P8 - New Part

models: 1999 - 2000 (BR/BE) Ram Truck

NOTE. THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 5.9L DIESEL ENGINE.

Discussion:

A customer may complain of 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.

NOTE: DO NOT CONFUSE THE HEAVY OIL OR FUEL-LIKE ODOR WITH A DIESEL ENGINE EXHAUST ODOR.

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 to exhibiting the odor condition.

NOTE: THE DAIMLERCHRYSLER RECOMMENDED DIESEL ENGINE OIL, P/N 04798231 (QT.) OR P/N 0479832 (GAL.), IS FORMULATED TO MINIMIZE THE HEAVY OIL ODOR CONDITION.

To possibly reduce the further incidence'of the odor condition, the integrity of the cowl seal should be verified. The cowl seal is located between the rear edge of the hood and the cowl panel. Diesel engine oil vapors, which develop during normal engine operation, exit the engine through the engine road draft tube. The heavy oil or fuel-like odor may leak past an opening in the cowl seal and enter the passenger compartment through the HVAC system. This may occur more frequently if the vehicle is at a stop, with the engine running, and the HVAC system is being operated in any mode other than "Re-circulate".

NOTE: ANY OPENING OR VOIDS IN THE COWL SEAL SHOULD BE CORRECTED. VERIFY THAT FULL CONTACT BETWEEN THE HOOD AND COWL SEAL IS PRESENT ALONG THE ENTIRE LENGTH OF THE SEALING SURFACES. PAY PARTICULAR ATTENTION TO THE SEALING INTEGRITY AT BOTH ENDS OF THE COWL SEAL.

Notes:

POLICY. Information Only

TSB 14-002-03 Diesel Transfer Pump Diagnosis

Overview: 
Improved diagnostic procedures are available which will greatly improve identifying a faulty fuel transfer pump. The improved procedures test the 'flow" capability of the transfer pump. It sufficient fuel reaches the injection pump from the low-pressure system, then the cause of engine performance problem(s) lies elsewhere.

Equipment Required:

Diagnostic Procedure:

The following procedure is to aid in evaluating the low-pressure fuel system performance in the absence of fault codes.

1. Inspect all fuel lines (including chassis) for kinks and leaks. Repair prior to proceeding.

2. Battery voltage must be greater than 11.5 volts. If not, charge batteries as required.

3. Remove the rubber fuel hose from the outlet side of the fuel filter (Fig, 1).

4. Attach a 915 mm (36 in.) clear hose to the fuel filter outlet line (Fig. 1). Do not use the pressure test fitting.

5. Route the hose to a clean, empty 3.8 liter (1 gallon) approved diesel fuel container.

6. Purge all air from the lines by bumping the starter to activate the transfer pump (transfer pump should run for 26 seconds).

WARNING! THE TRANSFER PUMP WILL RUN LESS THAN 2 SECONDS (VARIES WITH ECU CALIBRATION) WHEN THE IGNITION KEY IS FIRST TURNED TO ON. WHEN THE STARTER IS BUMPED (DO NOT ALLOW THE ENGINE TO START), THE TRANSFER PUMP WILL RUN 25 SECONDS. IF THE ENGINE HAS BEEN RUNNING, THE IGNITION KEY MUST BE CYCLED TO ALLOW THE TRANSFER PUMP TO RUN.

7. If the transfer pump runs, proceed to step 8. If the transfer pump does not run, check electrical circuits as follows:

a. Verify 12 volts are present across the transfer pump connector Use test light to verity current flow.

b. If 12 volts are present - Measure the resistance across the transfer pump. If greater than 200 ohms or less than 0.2 ohms, replace transfer pump.

8. Empty the container of fuel.

9. Bump the starter to activate the transfer pump. Look for air bubbles. If no air bubbles are present, proceed to step 10. If bubbles are present, check the lines/connectors between the fuel tank and the transfer pump for conditions allowing air to be drawn into the fuel system. Correct the condition and repeat steps 6, 8, and 9.

10. Measure the amount of fuel in the container after the pump shuts off. If the amount of fuel in the container is GREATER than 1.33 liters (45 fluid ounces) and the fuel is bubble free, then the low-pressure fuel system is OK, the cause of engine performance problem lies elsewhere. No further testing of the low pressure fuel system Is required. If the amount of fuel in the container is LESS than 1.33 liters (45 fluid ounces), proceed to step 11.

11. Connect fuel pressure test gauge #6828, included In the #6i977 Diesel Fuel Pressure kit, to the pressure fitting located on the fuel filter inlet. If the vehicle is a 2002 model, install test fitting #6976, included In the #6977 Diesel Fuel Pressure kit.

12. Purge all air from the lines by bumping the starter to activate the transfer pump. Empty the container of fuel.

13. Bump the starter to activate the transfer pump for 25 seconds. Observe the hose for air bubbles. Record filter inlet pressure.

a. If fuel filter inlet pressure is greater than 34.8 kPa (5 psi), replace the filter element, and repeat step 12 & 13.

b. If bubbles are present, check the lines/connectors between the fuel tank and the transfer pump for conditions allowing air to be drawn into the fuel system. Correct the condition and repeat step 12 & 13.

c. If fuel inlet pressure is less than 34.8 kPa (5 psi), proceed to stop 14.

14. If the fuel quantity continues to be LESS than 1.33 liters (45 fluid ounces), connect a fuel vacuum test gauge #6828 using the fuel pressure test adapter #6631 between the transfer pump and the chassis mounted fuel lines.

15. Purge all air from the lines by bumping the starter to activate the transfer pump.

16. Empty the container of fuel.

17. Bump the starter to activate the transfer pump for 25 seconds. Observe the hose for air bubbles. Record transfer pump inlet vacuum.

a. If inlet vacuum is greater than 152.4 mm/Hg (6 in/Hg), excessive restriction exists between the tank and the transfer pump. Inspect/repair the chassis fuel lines and/or fuel tank module for kinks and/or restrictions. After correcting the restriction, repeat steps 15, 16, & 17.

b. If bubbles are present, check the lines/connectors between the fuel tank and the transfer pump for conditions allowing air to be drawn into the fuel system. Correct the condition and repeat step 15, 16, & 17.

c. If the fuel quantity continues to be LESS than 1.33 liters (45 fluid ounces) and no

Models: 1998 1/2-2002 BR/BE Ram Trucks

NOTE: THIS BULLETIN APPLIES TO ALL RAM TRUCKS BUILT AFTER DECEMBER 17,1997 AND EQUIPPED WITH THE 24-VALVE 5.9L CUMMINS DIESEL ENGINE.

Discussion:

This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software (Cal 55Tl8, 57Tl1, 56Tl3, 59T7b, and 59T8b.)

Symptom/Condition:

Extended idle operation, especially in cold weather, can lead to stuck valves and bent push-tubes due to insufficient cylinder heat. This allows varnishes/oils to condense on the exhaust valve stems, leading to stuck valves, and damaged valve train components. A new software feature, enabled or disabled through the DRB III (See instructions under Repair Procedure), reduces the chance of valve sticking and improves cab heat warm-up time.

Once enabled, idle speed will slowly ramp up from 800 rpm to 1200 rpm when all of the following conditions are met:

1. Intake Manifold Temperature less than 0°C (32°F) and,
2. Coolant Temp is less than 60°C (140°F) and,
3. The Transmission is in Neutral or Park and,
4. The Service Brake pedal is not depressed and,
5. Throttle = 0% and,
6. Vehicle Speed = 0 mph

Additionally, if Intake Manifold Temperature (IMT) is less than -9°C (15°F), and all of the parameters above are met, three of the cylinders will be shut off upon reaching 1200 rpm, creating a slight change in engine sound which is normal. This allows the engine to create increased heat in the cooling system, allowing more rapid engine warm up and cab heating.

Both features will automatically disable when one of the following occurs:

1. The Automatic Transmission is placed in gear (forward or reverse) or,
2. The Service Brake pedal is depressed or,
3. Throttle position is greater than 0% or,
4. Vehicle Speed is greater than 0 mph or,
5. Coolant Temperature is greater than 79°C (175°F).

Engine speed will return to normal operation at 800 rpm. If the engine continues to idle and coolant temperature is at or below 60°C (140°'F), the feature will re enable. In order to operate properly, the Accelerator Pedal Position Sensor (APPS) must stay at idle.

NOTE: ANY TYPE OF AFTERMARKET IDLE SPEED KICKER THAT ACTIVATES THE APPS WILL DISABLE THIS FEATURE.

Use of the 110V block heater will not allow the feature to function after an overnight soak. If the vehicle is left idling, without use of the block heater, 1200 rpm operation will begin when the intake temperature drops below O°C (32°F) and coolant is less than 60°C (140°F).

Diagnosis:

1. Using the Diagnostic Scan Tool (DRBIII) with the appropriate Diagnostic Procedures, verify all engine/transmission systems are functioning as designed. If other Diagnostic Trouble Codes (DTC) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin.

Parts Required:

Equipment Required:

NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2090 OR HIGHER (2090 ARRIVES IN DEALERSHIPS ON SEPTEMBER 3, 2001).

Repair Procedure:

1. Log onto the MDS2 (Mopar Diagnostic System).

2. Connect the MDS2 and DRBIII to the vehicle and switch the ignition key to"ON".

NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III, MDS2, AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRB III" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A L4DS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK"BUTTON WHEN ASKED TO BEGIN SESSION.

3. Push the FLASH tab on the MDS2.

4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2.

NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION.

5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE.

6. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process.

NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED.

NOTE: ONCE THE VEHICLE HAS BEEN REPROGRAMMED TO THE PROPER SOFTWARE LEVEL, YOU MUST USE THE DRB III TO ENABLE THE 3 CYLINDER IDLE FEATURE. TO DO SO FOLLOW THE INSTRUCTIONS BELOW.

7. Connect the DRB III to the vehicle without connecting to MDS2 and follow the menu structures it appears below.

8. MAIN MENU - 1998 - 2002 DIAGNOSTICS

9. 1998 - 2002 DIAGNOSTICS - ALL (EXCEPT BELOW)

10. SELECT SYSTEM - 1 ENGINE

11. CONTROLLER TYPE - 1 CUMMINS (ECM/ENGINE)

12. SELECT FUNCTION - 1 MISCELLANEOUS (Misc. is on second page)

13. 3.3 CYLINDER IDLE - Follow the instructions

The DRB III will indicate whether the feature is enabled or disabled.
14. Push 1 to Enable, 2 to Disable.

15. You are instructed to cycle the ignition to complete the repair.

16. Press Page Back to Exit.

NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW.

17. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay.