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TSB 21-06-97 Rev. A

Overdrive Unavailable in Extreme Cold Temperatures,
Bypass Kit Installation, Inhibitor Programming

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Date: Dec. 19, 1997

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-06-97, DATED MAR. 21,1997 WHICH SHOULD BE REMOVED FROM YOUR FILES.

Models: 1996-l998    (BR/BE) Ram Truck

1996-1998   (AB)  Ram Van/Wagon
1996            (AN)  Dakota
1996-l998    (BR/BE) Ram Truck
1996-l998    (ZJ)    Grand Cherokee

NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES AND A 42RE, 44RE, 46RE, OR 47RE TRANSMISSION.

Symptoms:

At ambient temperatures of -20 C ( -5 F) or below, the Powertrain Control Module (PCM) will electronically inhibit the transmission from shifting into overdrive. This will protect the transmission from damage if the transmission fluid begins to freeze. In extreme cold climatic regions, this feature can cause customer dissatisfaction due to elimination of overdrive and less than optimal fuel economy.  

Diagnosis:

The cold weather by-pass kit along with disabling the inhibitor feature should only be incorporated for vehicles used in areas of extended cold ambient temperatures.

NOTE: THIS KIT WILL DECREASE THE MAXIMUM COOLING CAPACITY OF THE TRANSMISSION'S COOLING SYSTEM. AS A RESULT, IT IS NOT RECOMMENDED THAT THIS BULLETIN BE PERFORMED UNLESS THE ABOVE STATED CONDITION EXISTS. ALSO, IF THE VEHICLE IS USED FOR MODERATE TO HEAVY TOWING IT IS NOT RECOMMENDED.  

Parts/Equipment Required:

l          04798668 Kit, By-Pass V-10 Applications
1         04874284 Kit, Universal By-Pass (See Figure 1 for kit contents not posted)
AR (l) 04318044 Thread Sealant
1        CH6000 Scan Tool (DRB III I CH7035 General Purpose Interface Bus Cable (GPIB)
1        CH7000/7001 J 1 962 Cable
1        04669020 Label - Authorized Software Update
1        04275086 Label - Authorized Modification  

NOTE: THE MDS AND DRB III ARE ALSO REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED.

Repair:

This bulletin involves installing a cold weather by-pass kit to the transmission cooler circuit, selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes for 1996 models only), and using the DRB III to selectively turn off the overdrive inhibitor feature for all applications.

NOTE:    IT IS ESSENTIAL THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED.

NOTE:    EVEN WITH BYPASS KIT INSTALLATION AND THE INHIBITOR FEATURE TURNED OFF, 4TH GEAR WILL BE INHIBITED UNTIL THE OIL SUMP TEMPERATURE REACHES 0 C (30 F). THIS MAY TAKE SEVERAL MINUTES.

BYPASS KIT INSTALLATION

1.   Record all radio pre-sets and disconnect the negative battery cable.
2.    Raise the vehicle for access to the transmission housing. The bypass assembly will be connected to the existing transmission lines and mounted to the transmission housing by means of a bypass adapter.
3.    During this installation procedure, some transmission fluid will be lost when the transmission cooler lines are cut (allowing bypass assembly installation). Take proper precautions and check transmission fluid fill level upon completing the installation.

4.    If the cold weather bypass kit has provision for an in-line temperature sensor, the threaded "therm-o-well" (in the pressure "P" line of the kit) must be plugged with either the temperature sensor from the existing transmission line or the standard pipe plug provided. Consequently, if the vehicle being serviced is equipped with a temperature sensor (i.e., heavy duty BR truck), remove the temperature sensor from the existing line by un-threading and install it in the "pressure" line provided with the kit. Use Mopar Thread Sealant, p/n 04318044, to ensure a leak free seal.

5.    Disconnect the pressure and return lines from the transmission housing fittings.

6.    Remove and discard the fittings from the transmission housing.

7.    Apply Mopar Thread Sealant, p/n 04318044, to the threaded bypass adapter (#2 Figure 1).

8.    Install the threaded bypass adapter securely into the front pressure port of the transmission housing and torque to 17.6 Nm (1 3 ft. lbs.).

9.    Make sure the snap ring and 0-ring are properly installed in their respective grooves on the nose of the bypass assembly block. Lubricate the 0-ring with ATF.

10.   Position the bypass assembly block such that the return port fitting "R" is pointed directly up and the two other fittings are pointed forward.

11.   Firmly press the male nose of the bypass assembly into the female body of the threaded bypass adapter until it snaps into place. After snapping into place, the bypass assembly is permanently attached to the adapter.

NOTE:    THE BYPASS ASSEMBLY CAN ROTATE INSIDE THE ADAPTER, AND REMOVAL OF THE BLOCK FROM THE TRANSMISSION HOUSING (IF REQUIRED) CAN BE ACCOMPLISHED BY UN-THREADING THE ADAPTER.

CAUTION:    IF FLUSHING THE BYPASS ASSEMBLY IS REQUIRED, IT MUST BE REMOVED FROM THE TRANSMISSION HOUSING AND FORWARD FLUSHED ONLY. FAILING TO REMOVE THE VALVE AND REVERSE FLUSHING WILL RESULT IN TRANSMISSION FAILURE BY PLUGGING THE BYPASS VALVES INTERNAL ORIFICE AND DRAINBACK VALVE.

12.   Apply Mopar Thread Sealant, p/n 04318044, to the threaded end (transmission housing end) of the compression fitting.

13.   Install the threaded compression fitting securely into the rear return port of the transmission housing and torque to 17.6 NM (13 ft. lbs).

 

 Figure 2   Various Line Applications

14.  Using a small tubing cutter, cut the existing pressure line at approximately 120 mm (5 in.) from the transmission housing end. Repeat the procedure for the existing return line. CAUTION: AFTER CUTTING THE PRESSURE LINE, MARK IT WITH A PIECE OF TAPE FOR IDENTIFICATION.

15.   Identify the proper return line ("R" line) by using the marked labels attached to the tubes.

16.   Connect the "R" line to the bypass assembly block and the rearward return port of the transmission housing. Tighten the compression fitting finger tight, and then wrench tighten it an additional 112 turn. Tighten the inverted flare nut to 6.78 NM (60 in. lbs.).

17.   Select the appropriate "RR" and "P" tubes for the application. Mixing or matching may be required to provide the best routing for your application.

18.   Loosely connect the pressure line "P" to the pressure port fitting "P" on the bypass assembly block.

19.   Loosely connect the radiator return line, "RR" to the "RR" port fitting, on the bypass assembly block.

NOTE:    DURING THE INSTALLATION OF THE "P" AND "RR" LINES, THE ORDER MAY BE REVERSED TO AID IN THE ASSEMBLY PROCESS.

NOTE:    ON 5.2L ZJ MODELS, THE THROTTLE VALVE CABLE AND BRACKET MAY REQUIRE REMOVAL FOR BYPASS TUBE CLEARANCE. ONCE THE TUBES ARE INSTALLED LOOSELY, INSTALL THE BRACKET AND THROTTLE VALVE CABLE. MAKE ANY ADJUSTMENTS FOR CLEARANCE AND TIGHTEN THE BYPASS TUBES AND BRACKET ASSEMBLY.

20.   Make sure that the existing return line is properly re-attached to the hanger bracket and lay the new return line, "RR", beside it.

21.   Install the hose bracket (#12 in Figure 1) required for the overhead line application. The bracket will replace the existing bracket at the starter mount location. It may require slight modification to provide the best clearance from the exhaust system.

22.   Attach clamp (#l 1 in Figure 1) and the rubber hose to the "RR" tube to determine the approximate rubber hose routing. For connection to the existing return line, the line may be cut again to provide optimum line routing.

CAUTION:    WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM.

23.   Cut the rubber hose so that it has sufficient length to be attached to the existing return line.

24.   Loosely connect a nut (#7 in Figure 1), a compression sleeve (#8 in Figure 1), and a hose fitting (#10 in Figure 1) to the existing return line.

25.   Using a clamp (#l 1 in Figure 1), install the rubber hose onto the hose fitting (#l 0 in Figure 1).

26.   Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Make modifications as necessary to provide the best routing.

27.   Disconnect the "RR" tube from the Bypass Block for access to the "P" port on the block assembly.

28.   Attach a clamp and the rubber hose to the "P" tube and determine the approximate rubber hose routing. For connection to the existing pressure line, the line may be cut again to provide optimum line routing.

CAUTION:    WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM.

29.   Cut the rubber hose so that it has sufficient length to be attached to the existing pressure line.

30.   Loosely connect a nut (#7 in Figure 1), a compression sleeve (#8 in Figure 1), and a hose fitting (#l0 in Figure 1) to the existing pressure line.

31.   Using a clamp (#11 in Figure 1), install the rubber hose onto the hose fitting (#l0 in Figure 1).

32.   Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Use tie straps and rubber bumpers on the hose to protect the hose from metal surfaces that may cause chaffing.

33.   Torque both clamps, the compression fitting ( finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 NM (60 in. lbs.) on the "P" line.

34.   Connect the "RR" line and torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 NM (60 in. lbs.) on the "P" line.

35.   Re-check to ensure that all connections have been securely tightened and there is sufficient clearance around the exhaust system.

36.   If applicable, connect the wire harness to the temperature sensor.

37.   Lower the vehicle.

38.   Re-connect the negative battery cable and reset the radio stations recorded in step one.

39.   Check and adjust the transmission fluid level as outlined in the appropriate Service Manual.

40.   Raise the vehicle and check for leaks (idle in Neutral).

FLASH PROGRAMMING (1996 MODELS)

NOTE:    THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS UPDATE. THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED.

1.    Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up.

2.    Use the arrow keys and select #2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.

3.    Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.

4.    Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU.

5.    Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU.

6.    Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM.

7.    The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair.

8.    The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE:    THE FOLLOWING STEPS ARE REQUIRED BY LAW.

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

10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label.

PROGRAMMING COLD OVERDRIVE FEATURE (ALL APPLICATIONS)

Using the DRBIII, use the following procedures to program the overdrive cutoff feature.

1.    Connect the DRB III (Scan Tool) to the vehicle and power it up.

2.    Use the arrow keys and select #1 DRB III STANDALONE on the DRB III MAIN MENU Screen.

3.    Use the arrow keys and select #1 1994 - 1998 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU.

4.    Use the arrow keys and select #1 ENGINE on the DRB III SELECT SYSTEM MENU.

5. The module ID screen will appear, press enter to move to next menu.

6.    From the SELECT FUNCTION MENU, press the right arrow key for the next page and select #1 MISCELLANEOUS.

7.    From the SELECT MISCELLANEOUS FUNCTION MENU, press the right arrow key for the next page and select #1 COLD OVERDRIVE FEATURE.

8.    Follow the steps presented on the DRB III which will prompt you through the feature selection.

9.    When the password is asked for use- 84362172.

10.   Follow the remaining prompts for overdrive feature verification.

NOTE: IT IS IMPERATIVE THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED.

Notes:

POLICY:   Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No:    21-25-17-99 1996 AB/AN/BR/ZJ Models ............ 1.7 Hrs.
                                    21-25-17-99 1997 - 1998 AB/BR/BE/ZJ Models .... 1.5 Hrs.

FAILURE CODE: P8 - New Part


Thanks to Bob Bergevin and Barry Drodge for supplying this TSB information

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This page was edited on: May 3, 2004