Mopar1973Man

FRONT AXLE DISCONNECT SYSTEM 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: 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. When the vehicles is stopped in 2WD the front driveshaft will no longer spin freely. The 4WD indicator light on the instrument panel is now controlled by a switch on the transfer case. 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. 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. 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.

TOE IN SPECIFICATION CHANGE 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

The instrument cluster actuator test will put the instrument cluster into its self-diagnostic mode. In this mode the instrument cluster can perform a self diagnostic test that will confirm that the instrument cluster circuitry, the gauges, and the CCD data bus message-controlled indicators are capable of operating as designed. During the actuator test the instrument cluster circuitry position each of the gauge needles at various calibration points, illuminate each of the segments in the Vacuum-Fluorescent Display (VFD), and turn all of the CCD data bus message controlled indicators on and off. Successful completion of the actuator test will confirm that the instrument cluster is operational. However, there may still be a problem with the CCD data bus, the Powertrain Control Module (PCM), the Engine Control Module (ECM), the Airbag Control Module (ACM), the Controller Anti-lock Brake (CAB), or the inputs to one of these electronic control modules.Use a DRBIII scan tool to diagnose these components. Refer to the appropriate diagnostic information. 1. Begin the test with the ignition switch in the Off position. 2. Depress the odometer/trip odometer switch button. 3. While still holding the odometer/trip odometer switch button depressed, turn the ignition switch to the On position, but do not start the engine. 4. Keep the odometer/trip odometer switch button depressed for about ten seconds, until CHEC appears in the odometer display, then release the odometer/trip odometer switch button. 5. A series of three-digit numeric failure messages may appear in the odometer display, depending upon the failure mode. If a failure message appears, refer to the Instrument Cluster Failure Message chart for the description and proper correction. If no failure message appears, the actuator test will proceed as described in Step 6. 6. The instrument cluster will begin the Vacuum Fluorescent Display (VFD) walking segment test. This test will require the operator to visually inspect each VFD segment as it is displayed to determine a pass or fail condition. First, all of the segments will be illuminated at once; then, each individual segment of the VFD will be illuminated in sequence. If any segment in the display fails to illuminate, repeat the test to confirm the failure. If the failure is confirmed, replace the faulty instrument cluster. Following completion of the VFD walking segment test, the actuator test will proceed as described in Step 7. 7. The instrument cluster will perform a bulb check of each indicator that the instrument cluster circuitry controls. If the wait-to-start indicator does not illuminate during this test, the instrument cluster should be removed. However, check that the incandescent bulb is not faulty and that the bulb holder is properly installed on the instrument cluster electronic circuit board before considering instrument cluster replacement. If the bulb and bulb holder check OK, replace the faulty instrument cluster. Each of the remaining instrument cluster circuitry controlled indicators except the cruise indicator are illuminated by a Light Emitting Diode (LED). If an LED or the cruise indicator in the VFD, fails to illuminate during this test, the instrument cluster must be replaced. Following the bulb check test, the actuator test will proceed as described in Step 8. 8. The instrument cluster will perform a gauge actuator test. In this test the instrument cluster circuitry positions each of the gauge needles at three different calibration points, then returns the gauge needles to their relaxed positions. If an individual gauge does not respond properly, or does not respond at all during the gauge actuator test, the instrument cluster should be removed. However, check that the gauge terminal pins are properly inserted through the spring-clip terminal pin receptacles on the instrument cluster electronic circuit board before considering instrument cluster replacement. If the gauge terminal connections are OK, replace the faulty instrument cluster. 9. The actuator test is now completed. The instrument cluster will automatically exit the self-diagnostic mode and return to normal operation at the completion of the test, if the ignition switch is turned to the Off position during the test, or if a vehicle speed message indicating that the vehicle is moving is received from the PCM on the CCD data bus during the test. 10. Go back to Step 1 to repeat the test, if required.