TSB 21-12-97

Transfer Case Shifter Buzz or Rattle

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Models:  1996 - 1997 BR Ram Truck

Symptoms:

A buzz or clatter may be heard from the 4X4 transfer case shifter at an engine speed of aprox 2000 RPM.  The condition may worsen when the engine is under a load.

NOTE: THE BUZZ OR RATTLE WILL BE MORE NOTICEABLE ON VEHICLES EQUIPPED WITH THE 5.9L CUMMINS DIESEL.

Diagnosis:

Drive the vehicle to aprox 50 mph. Shift manual into OD or on automatic allow OD and torque converter to engage.  Accelerate to an engine speed of aprox 2100 rpm.

NOTE:  VEHICLES WITH AUTOMATIC TRANSMISSION MUST BE DIAGNOSED WITH TRANSMISSION IN OD AND TORQUE CONVERTER LOCKED.

Perform the repair procedure if a buzz or clatter is heard coming from the transfer case shifter.

Repair:

Bend the shift lever spring reaction tab outward to increase the spring tension on the shift lever.

1. Raise vehicle on a lift.
2. Locate the shift lever spring reaction tab on the shifter lever assembly (fig 1).
3. Using a suitable pry bar, bent the tab outward approximately 1/4 - 3/8 in  (fig 2).