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Date: Dec. 5,1997
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-29-97, DATED OCT. 17,1997 WHICH SHOULD BE REMOVED FROM YOUR FILES.
Models: 1996 - 1998 (BR/BE) Ram Truck
NOTE: THIS BULLETIN APPLIES TO THE 5.9L CUMMINS DIESEL WITH MANUAL TRANSMISSIONS ONLY.
Vehicle bucking or jerking during steady state operation or mild acceleration.
Some vehicles may exhibit a bucking or jerking condition while under light acceleration or while driving at steady state speeds. The vehicle may be in a loaded or unloaded state when the bucking or jerking occurs. This condition results from the sensitivity of the throttle linkage to driver input. If this situation is described by the owner, perform the Repair Procedure.
1 05011726AA Kit, Throttle Linkage
This bulletin involves replacing the throttle linkage and levers with revised parts.
1. Remove the air duct from the charge air cooler and intake manifold connection to gain access to the injection pump linkage. Place a rag over the open intake to prevent foreign objects from entering.
2. Disconnect the throttle cable and cruise control cable (if equipped) from the front throttle bracket assembly.
3. Remove the throttle control rod, front throttle bracket assembly, lever from injection pump arm, and all throttle return springs. Discard all parts.
4. From kit p/n 05011726AA, install the aluminum mounting block (Figure 1) to the injection pump arm using 2 bolts (M6 x 1.25 x 20). The cutout will face outwards. Torque the bolts to 9 Nm (60 in. lbs.).
5. From kit p/n 05011726AA, install the new rear lever to the aluminum block using 2 bolts (M6 x 1.25 x 16). The return spring mounts should be pointing down with the long mount facing outboard (Figure 1).
NOTE: DO NOT TIGHTEN THE MOUNTING BOLTS FOR THE REAR LEVER AT THIS TIME.
6. Install the 2 new throttle return springs from kit p/n 05011726AA to the rear throttle [ever mounts and pump mounts (Figure 2). No other springs are to be used with this installation.
NOTE: IF WORKING ON A 1996 VEHICLE, THE SPRING BRACKET (INCLUDED IN THE KIT) WILL BE REQUIRED TO MOUNT THE SPRINGS TO THE PUMP (FIGURE 1). REMOVE THE LOWER BOLT FROM THE TIMING PLUG HOLDER ON THE INJECTION PUMP (DO NOT DISTURB THE UPPER TAMPER PROOF SCREW). INSTALL THE BRACKET TO THE LOWER HOLE USING I (M8 X 1.25 X 22) BOLT. TORQUE THE BOLT TO 14 NM (10 FT. LBS.).
7. Install one throttle ball stud, from the kit, to the new front throttle bracket assembly. The ball must face inboard when the assembly is mounted in place. Torque the nut to 9 Nm (60 in. lbs.).
8. Snap the non-adjustable end of the throttle rod onto the front throttle bracket assembly and mount the assembly to the fuel injection pump with the existing bolts. Torque the bolts to 24 NM (15 ft. lbs.).
9. The rear lever must be set to the proper orientation by using the 219.9 mm gauge rod from the kit. Insert one end of the gauge rod into the rear throttle lever ball stud hole and the other end of the gauge in the large square throttle valve cable mounting hole in the front throttle bracket assembly (Figure 2). Make sure the injection pump lever remains seated against the idle stop. Tighten the rear throttle lever mounting screws to 7 NM (48 in lbs). Remove the gauge rod.
10. Install the remaining ball stud in the rear throttle lever. The ball should face outboard. Torque the nut to 9 NM (60 in. lbs.).
11. Snap the throttle rod onto the rear throttle lever ball stud.
12. Adjust the throttle rod length to 126.5 mm (5 in.) as shown in Figure 3. The measurement should be taken from the centerline of the front throttle lever ball stud and the front face of the bracket where the throttle cable mounts. Take up any slack by pushing lightly on the front lever when taking the measurement.
NOTE: MAKE SURE THE FRONT LEVER DOES NOT GO OVER CENTER WHILE PUSHING LIGHTLY.
13. After tightening the lock nut, operate the throttle and make sure there is no interference to the throttle rod. Make any up or down adjustments by loosening the lock nuts and orientating the throttle rod as necessary. Re-tighten the lock nuts.
14. Reinstall the throttle control cable and cruise control cable (if equipped).
15. Make sure wide open throttle (WOT) can be obtained. Follow the procedures in the applicable service manual.
16. Remove the rag at the intake and reinstall the duct to the charge air cooler and intake manifold. Torque the clamps to 8 NM (72 in. lbs.).
NOTE: MAKE SURE THE DUCT CLAMPS ARE TIGHT TO PREVENT TURBO BOOST LOSS.
POLICY: Reimbursable within the provisions of the warranty.
Labor Operation No: 14-80-05-90 ........ 0.6 Hrs.
Thanks to Bob Bergevin and Barry Drodge for supplying this TSB information
This page was edited on: May 3, 2004