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TSB 11-08-98

Turbo Diesel Wastegate Actuator Repair Kit

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Date:  Sep. 25, 1998

Models: 1994-98 BR/BE Ram with Cummins 5.9L engine

Discussion:

A new kit has been released that will allow technicians to repair turbos with failed wastegate actuators.  Wastegate actuators that have failed can cause low power complaints or noise complaints from air escaping out of the actuator.  The replacement seems to require the removal of the turbo from the exhaust path.  There are different parts kits for different years w/wo California emssions-see the TSB.

Diagnosis:

1. Remove air supply (signal) line from wastegate actuator (fig 1).

2. Install regulated air supply to actuator (fig 2).

 

3. Spray actuator assembly with soap solution and apply air pressure (45 psi Max) to the actuator.

4. If air leak can be heard or bubbles are seen, perform the repair.

5. If air leak is not detected and actuator rod does not move, remove e-clip at end of rod. Carefully disconnect the rod from the crank arm and check the crank arm for free movement. If arm is seized or does not move easily, replace turbocharger assembly.

Parts:

1    05013666AA    Actuator kit for 96-98 12V w/ CA emissions and manual or automatic.
1    05013667AA    Actuator kit for 95*, 96-98 12V w/ US emissions and automatic.
1    05013668AA    Actuator kit for 96-98 12V w/ US emissions and manual.
1    05013669AA     Actuator kit for 94-95* 12V - all.
1    05013670AA    Actuator kit for 98 24V - all.

NOTE: check wastegate actuator for short (approx 1') turbo-mounted air supply (signal) line, or longer (approx 3') engine mounted air supply line.

*USE 05013667AA for short turbo mounted configuration.
*USE 05013669AA for long engine mounted configuration.

Repair:

Replace failed wastegate actuator.

NOTE: THE NEW WASTEGATE ACTUATOR WILL HAVE A SPACER AND JAM NUT (FIG 3). MAKE SURE THE JAM NUT PAINT MARK HAS NOT CHANGED. IF THE MARK HAS BEEN MOVED, RETURN THE KIT FOR A NEW ONE.

1. Following service manual procedures, remove the turbocharger from the engine.

2. Remove air supply hose from the actuator and connect regulated shop air supply to actuator.

NOTE: Do not apply more than 45 PSI MAX into the actuator.

3. Remove the e-clip that attaches actuator end link to turbocharger crank arm.

4. The end link can now be easily removed from the crank arm.

5. Remove air supply and remove actuator from turbocharger.

6. Thread new end link from kit 4 or 5 turns into new actuator.

7. Fit end link over crank arm with the solid edge of the spacer facing away from the actuator mounting bracket. Push the crank arm toward the actuator (fig 4).

NOTE: DO NOT FIT ACTUATOR STUDS INTO MOUNTING HOLES AT THIS TIME.

8. Adjust the end link by rotating it on the actuator shaft until the body of the actuator just clears the bracket with less than 0.020" (0.5 mm) clearance (fig 5).

NOTE: THE ACTUATOR BODY MUST NO BE FORCED TO CLEAR THE MOUNTING BRACKET.

9. While holding the end link from rotating, remove the end link from the crank arm..

10. Install actuator studs through mounting holes of bracket and install the end link to the crank arm.

11. Attach the end link to crank arm with new e-clip and install new actuator mounting nuts onto actuator studs. Torque nuts to 75 in-lbs (8.5 Nm).

12. Loosen the jam nut that holds the spacer in place. Cut the tie strap and remove spacer.

13. Torque  jam nut against the end link to 75 in-lbs (8.5 Nm).

14. Connect air supply line to actuator and secure with new hose clamp.

15. Reinstall turbocharger to engine using new gaskets.

Time allowance: 0.8 hr.

 

Thanks to Bob Bergevin for providing this TSB information

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This page was edited on: May 3, 2004