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Models: 1999 - 2000 (BR/BE) Ram Truck
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A FEDERAL MARKET (NAA) 5.9L - 24V DIESEL ENGINE AND BUILT BETWEEN MARCH 2, 1999 (MDH 0302XX) AND OCTOBER 1, 1999 (MDH 1001XX).
This bulletin involves the replacement of the transmission valve body upper housing separator plate.
The customer may experience a condition where the transmission may seem to have a delayed 3-4 upshift, while moderately accelerating from 30 to 50 MPH (48 to 80 KM/H). The customer may also note high engine rpm's while operating in 3rd or 4th gear. This condition may be caused by a delay in the engagement of the transmission torque converter clutch (torque converter lockup).
1. If a delayed upshift condition is experienced, then use the DRB III Scan Tool build a Custom Display
2. Make certain that the ignition switch is in the "ON" position and the engine is not running.
The following selections may be made by either pressing the corresponding number or by moving the cursor to the appropriate item and then pressing ENTER key.
3. From the MAIN MENU, select DRB III Standalone (#1).
4. From the STAND-ALONE MAIN MENU, select 1998-2001 Diagnostics (#1).
5. From the SELECT SYSTEM, select Engine (#1).
6. From the ENGINE SELECTION, select JTEC (PCM I Non-Engine) (#2).
7. Use the ENTER key to page past the MODULE DISPLAY and the LEARNED STATUS.
8. From the SELECT FUNCTION, select Custom Display (#7).
9. From the CUSTOM DISPLAY Menu, select Custom Display #1 (#1).
10. From the CUSTOM DISPLAY, select Change (#2).
The technician is now able to assemble a custom display from the available Sensors or the Inputs/Outputs menus. This is accomplished by placing the cursor on the appropriate row and pressing the ENTER key. The technician is then offered a choice of the following menus: Sensors (#1), Inputs/Outputs (#2), or Not Selected (#3).
Assemble the Custom Display in the following order:
1 .PCM Engine RPM (found in the Sensors Menu)
2. Output Shaft Speed (found in the Sensors Menu)
3. Desired TC Clutch (found in the Inputs/Outputs Menu)
4. APP Pedal Position Volts (found in the Sensors Menu)
5. O/D Off Lamp (found in the Inputs/Outputs Menu)
6. Brake Switch (found in the Inputs/Outputs Menu)
7. Park/Neutral (found in the Inputs/Outputs Menu)
11. Once the Custom Display has been completely assembled, use the "Page Back" key to back out of the assembly section of the Custom Display feature.
12. From the Custom Display #1 Menu, select View (#1) to display the list of Custom Display values that have been created.
13. Make certain that the engine and transmission are at normal operating temperatures.
14. With the ignition switch in the "ON" position and engine stopped, press the O/D (overdrive) disable button on the shifter handle. This will prevent 4th gear from being able to be engaged.
15. Verify that the O/D Off Lamp display reads "ON / 3-Speed". 16. Observe the APP Pedal Position Volts and record the value (volts) when the throttle is closed.
NOTE TO PERFORM THE DIAGNOSTIC TEST CORRECTLY, THE TECHNICIAN MUST ACCELERATE THE VEHICLE WHILE MAINTAINING A SPECIFIC THROTTLE POSITION VOLTAGE (CALLED THE DIAGNOSTIC TEST RANGE VOLTAGE). THE TECHNICIAN MUST PERFORM TWO CALCULATIONS TO OBTAIN THE CORRECT VOLTAGE RANGE TO PERFORM THE DIAGNOSTIC TEST. WITH THE THROTTLE CLOSED, OBTAIN THE "APP PEDAL POSITION VOLTS" READING. THE "APP PEDAL POSITION VOLTS" MUST BE ADDED TO A MINIMUM INITIAL TEST RANGE VOLTAGE AND A MAXIMUM INITIAL TEST VOLTAGE. THE MINIMUM INITIAL TEST RANGE VOLTAGE IS 0.6 VOLTS AND THE MAXIMUM INITIAL TEST RANGE VOLTAGE IS 0.9 VOLTS. ADD THE CLOSED THROTTLE "APP PEDAL POSITION VOLTS" TO EACH OF THE INITIAL TEST RANGE VOLTAGES TO OBTAIN THE DIAGNOSTIC TEST RANGE VOLTAGE.
If the APP Pedal Position Volts at closed throttle is 0.5 volts, then add 0.5 volts to the initial minimum and maximum test range voltages (0.6 volts and 0.9 volts) to obtain the diagnostic test range voltages (1.1 volts to 1.4 volts). The technician would accelerate the vehicle, in this example, while maintaining an APP Pedal Position Voltage of between 1.1 volts and 1.4 volts.
17. Add the APP Pedal Position Volts, at closed throttle, to the minimum and maximum initial test range voltages to obtain the diagnostic test range voltages '
18. Start the engine. Press the O/D off button to turn off overdrive (prevent 4th gear).
NOTE: THE VEHICLE SHOULD BE DRIVEN IN A SAFE AREA AND IN A SAFE MANNER WHILE PERFORMING THE FOLLOWING DIAGNOSTIC TEST. OBSERVE ALL SPEED LIMITS.
19. Accelerate the vehicle while maintaining the APP Pedal Position Voltage within the diagnostic test range voltage (as calculated in step 17).
20. Verify that the Brake Switch is "Released", and the Park/Neutral reads "D/R".
21. Verify that the torque converter clutch command is being given. The Desired TC Clutch must read "LOCKED" within a few seconds after reaching 3rd gear.
22. Bring the vehicle to a stop. Accelerate the vehicle while maintaining the diagnostic test range voltage.
22. Continue the vehicle acceleration through the I - 2 shift and into the 2 - 3 shift. Again, make certain that the O/D Off Lamp reads "ON / 3-SPEED".
23. Monitor the Desired TC Clutch, the PCM Engine RPM, and the Output Shaft Speed values/reading as the transmission shifts from 2nd to 3rd.
24. When the "LOCKED" command is given by the PCM to the torque converter clutch (the Desired TC Clutch value reads "LOCKED"), the PCM Engine RPM and the Output Shaft Speed should be within +/- 30 rpm of each other within 5 seconds.
25. It may take a 3 or 4 accelerations to obtain a diagnostic conclusion.
26. If after 5 seconds following the TCC lockup command, the rpm difference between the PCM Engine RPM and the Output Shaft Speed is greater then +/- 30 rpm, then proceed with the Repair Procedure.
1 52118048AD Plate, Valve Body Upper Housing Separator
1 02464324AB Gasket, Transmission Oil Pan
10 05010124AA ATF +3, Transmission Oil (Type 7176E)
1 CH6000 Scan Tool (DRB 111)
1 CH7000/7001 J1962 Cable
1 . Inspect the new separator plate (p/n 52118048AD). The revised plate will have additional material removed (see hash marks in Figure 1) creating a wider slot (0.470 inch) to allow for increased fluid flow to the torque converter clutch.
2. Clean the separator plate to remove any dirt or rust inhibitor prior to installation.
3. Replace the transmission valve body upper housing separator plate and the transmission oil pan gasket (p/n 02464324AB). Refer to the appropriate year Service Manual, Section 21 - Transmission and Transfer Case for removal and installation instructions of the transmission valve body and its upper housing separator plate.
4. Verify fluid level after warming up the transmission and cycling the shift lever several times.
5. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures.
POLICY.- Reimbursable within the provisions of the warranty.
Labor Operation No: 21-95-01-92 ................................................... 1 .6 Hrs.
FAILURE CODE: P8-NewPart
Thanks to Bob Bergevin for supplying this TSB information
This page was edited on: May 3, 2004