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See also Recall #720, Extended Warranty Bulletin D-97-10
Date: Oct. 11, 1996
Models: 1995 - 1996 (BR) Ram Trucks
NOTE: THIS TECHNICAL SERVICE BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 5.9L CUMMINS DIESEL ENGINE WITH ENGINE SERIAL NUMBERS (ESN) 56230585 THROUGH 56293178 OR 45232867 THROUGH 45360437. THESE ENGINES WERE INSTALLED IN VEHICLES BUILT BEFORE JUNE 1, 1996 (MDH 06-OI-XX).
When the vacuum supply is contaminated by engine oil, any or all of the following may be customer concerns.
Some Ram Trucks equipped with the 5.9L Cummins Diesel engine were produced without a check valve on the vacuum pump. Without the check valve, oil may enter the vehicle's vacuum system during extended engine idling conditions, accumulating in areas of the vacuum harness that are lower than the suction port on the vacuum pump. With the engine OFF, this accumulation of oil can be pulled through the vehicle's vacuum system, contaminate vacuum actuated devices, and eventually cause the device to malfunction.
Any customer concern related to the previous Symptoms/Conditions should have the ESN inspected to verify whether or not the engine is within the suspect range. The ESN can be found on the Engine Data Plate, located on the left side of the timing cover housing, next to the oil fill tube (Figure 1). The ESN ( also known as the Engine No) is located to the right of the Timing TDC Specification.
If the ESN is within the suspect range, perform the following Repair Procedure. Also, a complete visual inspection of the vacuum system should be performed. Visually inspect the following vacuum actuated systems for contamination of engine oil at each vacuum port.
Any portion of the vacuum system contaminated by engine oil should be repaired or replaced. Refer to the 1996 Ram Truck Service Manual (Publication No. 81-377-6108), Group 24 for servicing of the HVAC vacuum system, Group SH for servicing of the speed control system, and Group 3 for servicing of the front axle motor disconnect.
NOTE: ALL VACUUM ACTUATED COMPONENTS MUST BE INSPECTED FOR CONTAMINATION FROM ENGINE OIL AND PROPERLY SERVICED PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER.
1 04883793AA Check Valve Package
This bulletin involves installing an external check valve onto the vacuum pump and replacing the main vacuum harness.
1. Disconnect the 118 in. diameter HVAC vacuum supply hose from the in-line vacuum "T" connector on the main vacuum supply hose.
2. Remove and discard the 318 in. main vacuum supply hose.
3. Remove the vacuum nipple at the vacuum pump and discard the nipple.
4. Install the check valve onto the vacuum pump. Tighten the check valve to 38 ft. lbs (52 Nm) of torque.
5. Install hose clamp onto main vacuum supply hose. Install main vacuum supply hose onto the vacuum pump external check valve. Properly position and tighten the hose clamp.
NOTE: POSITION IN-LINE "T" CONNECTOR SO THAT THE HVAC PORT IS POINTING UPWARD BEFORE TIGHTENING THE CLAMP.
6. Route the main vacuum supply hose over the top of the power steering hoses and tie strap the vacuum harness to the engine wiring harness located near the rear of the fuel injection pump.
7. Install a hose clamp onto the main vacuum harness and connect the main vacuum harness to the power brake booster check valve. Tighten the hose clamp.
8. Connect the 1/8 in. diameter HVAC vacuum supply hose to the in-line vacuum "T" connector on the main vacuum harness.
POLICY: Reimbursable within the provisions of the warranty. **
Labor Operation No: 24-50-47-92 ................................. 0.5 Hrs
FAILURE CODE: PS - New Part
Subject: CC TSB and Recall re: vacuum
Date: Wed, 21 Jan 1998 15:18:46 -0500
From: bob bergevin <bergevin@SLIC.COM>
To: . cummins
-- Clarence Patton makes several comments that do need some further relevant information. It appears that his '96 Cummins 3/4 was recalled for a "...vacuum check valve recall". For everyone's information this was Chry Co recall # 720, and is on file in every Dodge dealer's recall file folder. In addition a CC TSB (technical Service Bulletin) was issued on October 11, 1996, and carries TSB # 24-16-96 with much of the same information of recall 720, and the recall notice made reference to the TSB that preceded it. The TSB identified the series of vehicles involved, (those with engine serial #'s 56230585 thru 56293178 or from 45232867 thru 45360437 [2 groups as there are 2 Cummins assembly plants for the 5.9L model] some 190,000 engines) installed in vehicles built BEFORE June 1, 1996 (or 0601xx as displayed on the driver door jamb decal listed MDH, or month day and hour of final assembly).
On page three of the TSB in caps, "...ALL VACUUM ACTUATED COMPONENTS MUST BE INSPECTED FOR CONTAMINATION FROM ENGINE OIL AND PROPERLY SERVICED PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER."
The TSB was published first, and the recall to inspect and install the check valve was made during the summer /fall of 1997 almost 1 year AFTER the TSB. List member Patten writes, "...the dealership finally concluded that all the vacuum hose connections were contaminated...and had to be replaced. As the service department explained, CC did the check valve recall, but did not make provisions to check other rubber components throughout the vacuum system."
NOT TRUE - both the TSB and the Recall notice CLEARLY and IN CAPS, stated to "...be inspected and ...properly serviced prior to returning...to the customer." Find your dealer, find his Recall notice file, and read #720, and find the TSB #24-16-96 and read that one. Your service department did not read the TSB and probably didn't read much of the Recall notice. If you spent your $30,000 +/- with him for your Ram, find another dealer who cares how he supports his customers. Mine took mine in and spent almost 10 hours replacing all the vacuum servos in the vehicle as they were all contaminated. No easy task as they are mostly behind the dash for the HVAC system.
Owners of a used Cummins/Dodge built prior to June 1, 1996 (MDH 0601xx on the drivers door jamb decal, look for it carefully it also has the recommended tire pressures and other loading info on it as well) can check to see if their vehicle has had any or all the recalls done and who did them by going to their Chrysler dealer with their VIN and asking the service department to run their VIN through function 14 on the DIAL System to Chrysler. The resulting summary will give a wealth of information regarding warranty info remaining, and recall history according to the CC records. If it ain't on there, it was never done.
Remember, a recall is done to correct a safety aspect of the vehicle and requires notification of all affected in the group. A TSB is issued to correct a technical problem in a vehicle or procedure that has been found that may affect the operation and satisfaction of a vehicle by its operator. TSB's are not usually used to locate every model that MAY have that problem. Each is handled on a need-to-find-out basis. TSB's are located by making an inquiry from the VIN for a specific problem. They are also sent to the service departments and printed in a bound volume the dealer has somewhere in backfile form.
Thanks to Bob Bergevin and Barry Drodge for supplying this TSB information
This page was edited on: May 3, 2004