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TSB 06-01-94

Transmission Noise Below 1400 RPM

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Models: 1989 - 1993 (AD) Ram Pick Up/Ram Cab & Chassis

THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 5.9L DIESEL ENGINE AND GETRAG MANUAL TRANSMISSION.

Symptoms:

Some 1989 to 1993 Ram trucks equipped with the 5.9L Cummins diesel and manual transmission my exhibit a powertrain induced cyclic groaning or harsh noise condition that appears to be transmission or driveline related. The noise condition is noticeable in all gears, but is especially noticeable in fourth and fifth gears. The noise condition will occur below 1400 RPM during float, coast, or light throttle operation.

The noise is not damaging to the powertrain and is due to the dampening characteristics of the clutch springs.  

Diagnosis:

1.    Road test the vehicle a sufficient distance to ensure that the transmission has reached normal operating temperature.

2.    Evaluate the vehicle for the noise condition in each gear during float, coast, and light throttle operation.

3.    Record the vehicle speed (MPH), in each gear, when the noise condition is no longer present.

4.    Compare your recorded MPH readings in each gear with the recommended minimum operating gear selection chart below.

GEAR	AXLE RATIO
	3.54 Axle Minimum Speed	4.10 Axle Minimum Speed
First	5 MPH	4 MPH
Second	10 MPH	9 MPH
Third	20 MPH	17 MPH
Fourth	30 MPH	26 MPH
Fifth	45 MPH	40 MPH

5.    If an objectionable noise condition is present at speeds ABOVE the minimum recommended gear selection speed (MPH) on the chart, perform the following repair procedure.

6.    If the noise condition is ONLY present at speeds BELOW the minimum recommended gear selection speed (MPH) on the chart, no repair is required. Perform a road test with the vehicle owner, using the recommended gear selection speeds, to ensure that the owner understands that the noise condition is the result of driving technique and not a problem in the transmission or powertrain system.

Parts:

1   04778414    Disc, Clutch
4   06024473    Bolts (If Required)  

Repair:

This bulletin involves the removal and replacement of the clutch disc.

1.    Disconnect the battery negative cable.

2.    Remove the shift lever boot and seal.

3.    Remove the snap ring in the shift tower that retains the stub shifter and shifter seat.

4.    Remove the snifter seat and shift lever/stub shifter assembly from the shift tower.

5.    Raise the vehicle.

6.    Mark the propeller shaft(s) universal joint, transmission and axle yoke for alignment reference during reassembly.

7.    Remove the propeller shaft(s).

8.    Disconnect the speedster cable, back up light wiring, and transfer case linkage (if equipped).

9.    Remove the exhaust support bracket located on the right side of the clutch housing.

10.   For 2WD Vehicles:    Support the transmission with a suitable jack. Remove the crossmember.

        For 4WD Vehicles:    Support the crossmember and transmission/transfer case assembly with a suitable jack. Using "C" clamps and a safety chain, secure the assembly to the jack. Remove the crossmember to frame bolts.

11.   Remove the four transmission to clutch housing bolts.

NOTE:    MEASURE THE BOLTS. IF THEY ARE 7/16-14 x 1 1/2 INCHES, THEY MUST BE REPLACED WITH P/N 6024473 (7/16-14 x 2 INCHES).

12.   Lower the transmission slightly. Move the assembly rearward until the input shaft clears the clutch housing and remove the transmission from under the vehicle.

13.   Remove the clutch release cylinder and its cover. Remove the clutch housing.

14.   Mark the clutch disc cover-to-flywheel position for future assembly reference.

15.   Loosen the clutch cover bolts evenly a few threads at a time to avoid warping the cover.

16.   Remove the clutch cover and clutch disc.

17.   Clean the friction face of the flywheel and clutch cover with a suitable solvent such as Mopar Brake and Carburetor Parts Cleaner, P/N 4318037. The friction faces must be free of dirt and oil. Do not clean the release bearing with any solvent.

18.   Inspect the pilot bushing. It should be smooth and show no excessive wear.

NOTE: IF THE PILOT BUSHING IS EXCESSIVELY WORN, THE CLUTCH HOUSING BORE AND FACE RUNOUT SHOULD BE CHECKED. REFER TO THE 1993 REAR WHEEL DRIVE TRUCK SERVICE MANUAL PAGE 6-3.

19.   Lubricate the pilot bushing with Mopar Multipurpose Grease, P/N 4318063.

20.   Install the clutch disc and clutch cover using a universal clutch alignment tool. Be sure to align the clutch cover mark with the flywheel mark made earlier during the disassembly process.

21.   Tighten the clutch cover bolts a few turns at a time to avoid warping the cover. Torque the 5/161, clutch cover bolts to 17 ft lbs. (23 Nm) and the 3/811 clutch cover bolts to 30 ft. lbs. (41 NM).

22. Clean the clutch housing and transmission adapter faces. They must be free of dirt and oil.

23.   Lubricate the clutch release lever ball pivot with Mopar Multipurpose Grease, P/N 4318063.

24.   Install the clutch housing. Torque the mounting bolts to 35 ft lbs. (47 NM).

25.   Install the clutch release cylinder and its cover. Tighten the clutch release cylinder attaching nut to 110 in. lbs. (12 NM).

26.   Install the exhaust support bracket.

27.   Install the transmission.

NOTE:   THE TRANSMISSION-TO-CLUTCH HOUSING BOLTS MUST BE OF PROPER LENGTH (7/16-14 x 2 INCHES).

28.   Apply Mopar Stud N' Bearing Mount, P/N 4318032, to the transmission bolt threads.

29.   Install the transmission bolts and torque the 7/1611 bolt to 65 ft. lbs. (88 NM) and the 1/2-1 bolt to 90 ft. lbs.(122 NM).

30.   Install the crossmember.

31.   Install the propeller shaft(s). Be sure to align the universal joint(s) with the yoke marks made during the disassembly process. Tighten the U- joint strap bolts to 14 ft. lbs. (19 NM).

32.   Install the speedometer cable and backup light wiring.

33.   Lower the vehicle.

34.   Install the stub shifter/shift lever assembly, shifter seat, and snap ring.

35.   Install the shift lever seal and boot. 36.   Connect the battery negative cable. 37.   Start the engine and check clutch operation.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No: 06-20-01-96 (2WD) . . . . . . . . . . . . . 2.2 Hrs.
                                                      (4WD) . . . . . . . . . . . . . 3.2 Hrs.

FAILURE CODE: P8 - New Part