TSB 18-02-99

Erratic Torque Converter Clutch (TCC) Operation (5.9L Diesel Applications)

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Date: Feb.19,1999

Models: 1998 - 1999 (BR/BE) Ram Truck

NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 5.9L 24 VALVE DIESEL ENGINE AND AUTOMATIC TRANSMISSION BUILT BETWEEN JAN. 1, 1998 AND DEC. 18,1998 (MDH 0101XX & 1218XX).

Overview:
This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes 98call2 & 99call4).

Symptom/Condition:
Some vehicles may experience a surge like condition while in 4th gear. This maybe caused by the Torque Converter Clutch (TCC) unlocking and locking when it should be consistently locked. The cause of this erratic operation has been identified as electrical noise from the Throttle Position Sensor (TPS) or Alternator.

Diagnosis:
Using the Mopar Diagnostic System (MDS/MDS2)  or the Diagnostic Scan Tool (DRB III), verify that all engine/transmission systems are functioning as designed. If other DTC's are present, repair as necessary before proceeding with this bulletin.   If no other DTC's are present, perform the repair procedure.

Verify the condition by creating a custom display in the DRB III" and include the following: SENSORS (Output Shaft Speed, TPS Volts, Trans Temp Degree) & INPUTS/OUTPUTS (Brake Switch, Park/Neutral, ASD Relay Sense, Desired TC Clutch).

Drive the vehicle with a helper monitoring the DRB III. Warm the engine and verify the transmission fluid temperature is greater than 32F and consistent. Operate the vehicle with an output shaft speed greater than 2200 rpm. Verify that the brake switch shows a released status that is consistent and verify the park/neutral status reads D/R and is consistent. While keeping the output shaft speed above 2200 rpm, hold the throttle so the TPS reads 1 volt. Monitor the TC clutch status, it should be consistently locked. If the TC clutch status shows unlocking/locking, look to see if the TPS volts are fluctuating by 0.2 volts or more. If the conditions are met, perform the Repair Procedure. If a surge like condition is felt but the above test does not confirm the TCC unlocking/locking occurrence, further diagnosis and testing will be required.

NOTE:  Whenever a PCM is replaced due to failure, the software of the replacement controller should be verified for the latest revision level. Use the flash procedure to updated replaced controllers as necessary.

Parts Required:

• 1       04669020 Label, Authorized Software Update
• 1       04275086 Label, Authorized Modification

Equipment Required:

• 1       CH6000 Scan Tool (DRB III)
• 1       CH7035 General Purpose Interface Cable (GPIB)
• 1       CH7000/7001 J1962 Cable
• 1                     MDS1 or MDS2

NOTE: The MDS1/MDS2 and DRB III are required to perform part of this repair. If using the MDS1 and DRB III the MDS must be operating with release 21 or higher AND TIL CD RELEASE 1179 or higher must be installed. If using the MDS2 and the DRB III the system must be operating at CIS CD2030 or higher.

Repair:
This Procedure involves selectively erasing and reprogramming the PCM with new software (99cal14 calibration change).

MDS 1 PROCEDURE:

1. Connect the MDS1 and DRB III to the vehicle and power them up.
2. Use the arrow keys to select #2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU SCREEN.
3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN MENU SCREEN.
4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU.
5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS1, then press NEXT MENU.
6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING THE MDS! & DRBIII on the MDS, then press NEXT MENU.
7. Following the steps presented on the MDS1 and DRB III that will allow the DRB III to obtain the current number of the PCM.
8. The MDS1 will display the vehicles PCM part number and the replacement part number(s). Press NEXT MENU to begin programming
   • NOTE: A no updates available message may be displayed. Check the ECM part number on the vehicle and compare it to the part number displayed on the MDS. If no updates are available, first check your diagnostic equipment for the latest software levels as listed earlier in this bulletin. If the latest software is installed, another vehicle condition exists that will require further investigation.
9. The MDS1 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process.

 

10. Type or print necessary info on the "Authorized Software Update" label (Fig 1) and attach it to the PCM. Cover the label with clear tape.

 

11. Type or print the following information on the Authorized Modification Label p/n 04275086 and attach the label near the VECI label (Fig 2).

  MDS2 PROCEDURES:

1. Log onto the MDS2 system.
2. Connect the MDS2 and DRB III to the vehicle and switch the ignition key to "ON".
3. Use the arrow keys to select #2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU SCREEN.
4. Use the arrow keys to select #2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN.
   • NOTE: Once MDS2, DRB II, and vehicle communication has been established, the "CANNOT READ VIN FROM DRB III" message on the MDS will be replaced by the vehicle VIN. Press the "OK" button on the MDS2 to request a MDS2 session for the vehicle VIN indicated. Press the "OK" button when asked to begin session.
5. Push the FLASH tab on the MDS2.
   • NOTE: A message may appear that indicates no updates are available. If this occurs, make sure your diagnostic equipment is operating at the latest software level as listed earlier in this bulletin. If the latest software is installed, and no updates are available, another vehicle condition exists that will require further investigation.
6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2.
   • NOTE: A message may appear that indicates no updates are available. If this occurs, make sure your diagnostic equipment is operating at the latest software level as listed earlier in this bulletin. If the latest software is installed, and no updates are available, another vehicle condition exists that will require further investigation.
7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE.
8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process.
   • NOTE: The following steps are required by law
9. Type or print necessary info on the "Authorized Software Update" label PN 04669020 (Fig 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type or print the following information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Fig 2).

Policy:           Reimbursable within the terms of the warranty.

Time Allowance:
Labor Operation No:     08-19-42-95 ............................. 0.5 Hrs.  

Failure Code:          FM -- Flash Module