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TSB 18-010-04

Flash: MIL Illumination Diagnostic Trouble Codes (DTC’s) P0403, P0404, P0405, P0406

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Date: March 2, 2004

Models: 2004 (DR) Ram Truck

2004 (DR) Ram Truck
2004 (HB) Durango

NOTE: This bulletin applies to DR and HB vehicles equipped with a 5.7L engine (sales code EZA) built on or before February 29, 2004 (MDH 0229XX).

Overview:
This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software.

Symptom/Condition:
The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC’s:

P0403-EGR CONTROL CIRCUIT

P0404-EGR POSITION SENSOR PERFORMANCE

P0405-EGR POSITION SENSOR LOW

P0406-EGR POSITION SENSOR HIGH

Diagnosis:
Using a Scan Tool (DRBIII) with TechCONNECT or the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin.

If the vehicle operator describes or experiences the Symptom/Condition, perform the appropriate Repair Procedure.

NOTE: There are three separate Repair Procedures. One for DR vehicles and two for HB vehicles.

NOTE: There are two methods to download flash files to StarSCAN. The first method is to download the flash files from the StarSCAN Software Update CD. The second method (NEW) is to download the flash files to the StarSCAN from the internet.

Parts Required:

Qty.	Part No.	Description
1	04275086AB	Label,   Authorized Modification

Special Tools/Equipment Required:

NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII connection. Use this cable whenever a flash is being performed.

Repair Procedure: 

NOTE: Whenever a controller is programmed, the software in the DRBIII must be programmed with the latest revision level available.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII.

Most owners do not have access to the software and equipment required to program the ECM. To see the specific instructions, download the pdf version.

NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC’s may cause the MIL to illuminate. Check all modules using “Module Scan”, record the DTC’s, and erase these DTC’s prior to returning the vehicle to the customer. Erase any DTC’s in the PCM only after all other modules have had their DTC’s erased.

NOTE: The following step is required by law.

Type the necessary information on the “Authorized Modification Label” p/n 04275086AB and attach near the VECI label (Figure 1).

FIGURE 1 - AUTHORIZED MODIFICATION LABEL 1 - POWERTRAIN CONTROL MODULE P/N (INSERT P/N) USED 2 - CHANGE AUTHORITY: TSB XX-XXX-XX 3 - DEALER CODE: XXXXX 4 - DATE: XX-XX-XX

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:

Failure Code:

This page was edited on: May 3, 2004