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Date: Sep. 1, 2000
This bulletin superseded TSB 21-19-99, which should be removed from your files.
Models: 1999-2000 BR/BE Ram Truck - diesel with automatic
NOTE: THIS APPLIES TO VEHICLES BUILT FOR CALIFORNIA MARKET (CODE NAE) AND EQUIPPED WITH 5.9L - 24V DIESEL ENGINE AND BUILT BETWEEN MARCH 2,1999 (MDH 0302XX) AND OCTOBER 1, 1999 (MDH 100199).
This bulletin involves the replacement of the transmission valve body upper housing separator plate.
The customer may experience a delayed torque converter clutch engagement (lock-up). This condition may illuminate the Malfunction Indicator Lamp (MIL) due to Diagnostic Trouble Code (DTC) Pl740 - TCC or O/D Solenoid Performance. In some situations, the customer may describe the condition as a lack of a transmission shift (TCC lockup) between 30 and 50 mph (48 to 80 KM/H).
The transmission valve body upper housing separator plate was revised, with a wider (12 mm or 0.470 in.) slot in the lockup vent circuit, to improve fluid flow to the torque converter clutch.
1. With a DRBIII (ScanTool),verify that the MIL is caused by Diagnostic Trouble Code (DTC) Pl740 - TCC or O/D Solenoid Performance.
2. If the MIL is due to DTC P1740, then with the DRB III, proceed to build a Custom Display. The Custom Display that is created will be used to monitor the engine speed input to the transmission and the transmission output speed when the torque converter clutch engagement occurs.
3. The Custom Display should include the following sensors and
a. PCM Engine RPM (found in the Sensors Menu)
b. Output Shaft Speed (found in the Sensors Menu)
c. Desired TC Clutch (found in the Inputs/Outputs Menu)
d. APP Pedal Position Volts (found in the Sensors Menu)
e. OID Off Lamp (found in the Inputs/Outputs Menu)
f. Brake Switch (found in the Inputs/Outputs Menu)
g. Park/Neutral (found in the Inputs/Outputs Menu)
4. Save the Custom Display for use during the road test portion of the diagnosis.
1. Start the engine.
2. With the DRB III, bring up the Custom Display that was created for this condition.
3. Make certain that the engine and transmission are at normal operating temperatures.
4. Press the O/D button on the shifter handle. This will prevent O/D engagement.
5. Verify on the Custom Display that the O/D Off Lamp display reads "ON / 3-SPEED".
6. Observe the APP Pedal Position Volts. Record the voltage value when the throttle is closed and the engine is at idle. This value is required to calculate how wide open the throttle must be when verifying TCC lock-up during the diagnostic road test.
When the diagnostic test is actually performed, the closed throttle (at idle) APP Pedal Position voltage must be added to the initial minimum and maximum test range voltages. The initial test range voltages are 0.6 volts (min) to 0.9 volts (max). Add the at idle closed throttle voltage from step 6 to each of the test range voltages to obtain the actual test range voltages. An example: if the APP Pedal Position Voltage at closed throttle is 0.5 volts, then add 0.5 volts to the initial test range voltages (0.6 volts and 0.9 volts) to obtain the actual diagnostic test range voltages.
An example: if the APP Pedal Position Voltage at closed throttle (and engine idling) is 0.5 volts, then add this reading (0.5 volts) to the initial test range voltages (0.6 volts and 0.9 volts) to obtain the actual diagnostic test range voltages of 1.1 volts and 1.4 volts respectively. In this example, the technician would accelerate the vehicle while maintaining an APP Pedal Position Voltage of between 1.1 volts (min.) and 1.4 volts (max.).
Add the APP Pedal Position voltage obtained in Step 6, to the initial test range voltages (0.6 volts and 0.9 volts) to obtain the actual diagnostic test range voltages.
8. Accelerate the vehicle while maintaining the APP Pedal Position Voltage within the actual diagnostic test range (as calculated in step 7).
NOTE: THE VEHICLE MUST BE DRIVEN IN A SAFE AREA AND IN A SAFE MANNER WHILE PERFORMING THE FOLLOWING DIAGNOSTIC TEST. OBSERVE ALL SPEED LIMITS.
9. Verify that the Brake Switch is "Released", and that the Park/Neutral reads "D/R".
10. Verify that the torque converter clutch command is being given. The Desired TC Clutch must read "LOCKED" within a few seconds of reaching 3rd gear.
11. Bring the vehicle to a stop with engine idling. Accelerate the vehicle while maintaining the APP Pedal Position voltage within the actual diagnostic test range voltages that were calculated in Step 7.
12. Continue to accelerate the vehicle through the 1-2 upshift and into the 2-3 upshift. Again, make certain that the OID Off Lamp reads "ON / 3-SPEED".
13. Monitor the Desired TC Clutch, the PCM Engine RPM, and the Output Shaft Speed values/readings as the transmission shifts from 2nd to 3rd.
14. The PCM Engine RPM and the Output Shaft Speed values should be within +/- 30 rpm of each other within 6 seconds following the command from the PCM to lockup the torque converter clutch (Desired TC Clutch reads "LOCKED").
15. It may take three or four accelerations (Steps 11 through 14) to obtain a good diagnostic conclusion.
16. If the rpm difference between the PCM Engine RPM value/reading and the Output Shaft Speed value/reading is greater than +/- 30 rpm after 6 seconds following TCC lock-up in 3rd gear, then perform the Repair Procedure. If the difference before 6 seconds is less than + 30 rpm, then further diagnosis is required.
52118048AD Plate, Valve Body Upper Housing Separator
1 05012978AB Gasket, Transmission Oil Pan
AR (10) 05010124AA ATF + III, Transmission Oil Type 7176
Scan Tool (DRB III)
1 CH7000/7001 J1962Cable
1. Inspect the new separator plate (p/n 52118048AD). The revised plate should have a 12mm or 0.470 inch wide slot to allow for the torque converter clutch lock-up vent circuit. Figure 1.
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 05012978AB). 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.
1 - SPECIAL IDENTIFICATION HOLE TO IDENTIFY REVISION
POLICY. Reimbursable within the provisions of the warranty.
Labor Operation No: 21-95-01-92 .............................. 1.6 Hrs.
FAILURE CODE: P8 - New Part
Thanks to Bob Bergevin for supplying this TSB information
This page was edited on: May 3, 2004