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TSB 09-002-01

Use Of Exhaust Manifold Bolt Retention Straps To Prevent Torque Loss

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Date: Mar. 02, 2001

Models: 1998 - 2001 (BR/BE) Ram Truck

NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 5.9L-24V DIESEL ENGINE BUILT ON OR BETWEEN ENGINE SERIAL NUMBER 56419738 AND 56777585, WITH A DATE OF ENGINE MANUFACTURE FROM JANUARY 01, 1998 TO SEPTEMBER 22, 2000. THIS INFORMATION IS AVAILABLE ON THE ENGINE DATA PLATE, WHICH IS LOCATED ON THE LEFT SIDE OF THE ENGINE, AFFIXED TO THE SIDE OF THE TIMING GEAR HOUSING.

Discussion:
This bulletin involves the installation of retention straps to cylinders I & 2 and to cylinders 5 & 6 exhaust manifold bolts.

Symptom/Condition:

Vehicles that are used for extended heavy trailer hauling purposes may experience a loss of exhaust manifold bolt torque. This condition may lead to exhaust gas blow-by past the exhaust manifold gasket(s) and even loss of exhaust manifold bolts.

A new exhaust manifold bolt retention strap has been released as a means of locking the outboard exhaust manifold bolts in place. This will prevent bolt rotation and torque loss during the thermal expansion and contraction cycles of the exhaust manifold.

Diagnosis:

1 .Inspect the exhaust manifold bolts and exhaust manifold gaskets.

2. If any exhaust manifold bolts or gaskets are missing or damaged, then replace or repair the necessary parts prior to performing this TSB.

3. If the exhaust manifold bolts are in place for cylinders 1, 2, 5, and 6, and there is no damage to the exhaust manifold gaskets, then perform the Repair Procedure.

Parts Required:

Qty.	Part No.	Description
1	05072387AAA	Straps, Exhaust Manifold Bolt Retention (set of 4)

Repair Procedure:

1. Remove the remote air cleaner assembly and the turbo air inlet duct, if not removed earlier.

2. Remove the cab heater return pipe nut from the exhaust manifold stud. Position the tube out of the way.

3. Verify that all exhaust manifold bolts are at the specified torque of 43 Nm (32 ft. lbs.).

NOTE: THE RETENTION STRAPS FIT ON TOP OF THE BOLT HEAD, NOT UNDER THE HEAD OF THE BOLT. THE REMOVAL OF THE EXHAUST MANIFOLD BOLT IS NOT NECESSARY TO INSTALL THE RETENTION STRAP.

NOTE: THE RETENTION STRAP IS NOT REUSABLE (ONE TIME USE). THE RETENTION STRAP MUST BE INSTALLED CORRECTLY THE FIRST TIME.

NOTE: INSTALL THE RETENTION STRAP ONTO THE BOLT HEAD UNTIL IT JUST BEGINS TO CONTACT THE BOTTOM OF THE BOLT HEAD. INSTALLING THE STRAP TOO FAR ONTO THE BOLT HEAD MAY CAUSE THE HOLE IN THE STRAP TO EXPAND TOO MUCH AND BECOME LOOSE.

4. Position the strap across cylinder one and two upper exhaust manifold bolt heads. Using a 14mm socket and hammer, tap the retention strap onto the head of each bolt. Be careful not to overseat the strap (Fig. 1).

Fig. 1 RETENTION STRAP INSTALLATION

1 - Turbo Charger 2 - Cylinder Two Exhaust Manifold Bolts 3 - Retention Straps - Cyl. 1 & 2 4 - 14mm Socket and Hammer

5. Repeating step 4, install a retention strap to cylinder one and two lower exhaust bolts, and to the upper and lower exhaust bolts for cylinder five and six (Fig. 2).

Fig. 2 INSTALLED RETENTION STRAPS

1 - Transmission Oil Dipstick 2 - Turbo Charger 3 - Installed Retention Straps - Cyl 5 & 6

6. Install the cab heater return hose to the exhaust manifold bolt stud. Tighten the nut to 24 Nm (18 ft. lbs.).

7. Install the remote air cleaner assembly and turbo air inlet duct.

Notes: 

Policy:    Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No:
09-45-01-93          Install Bolt Retention Straps           0. 2 Hrs.

FAILURE CODE:
P8     New Part

This page was edited on: May 3, 2004