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TSB 11-005-05

Bulletin subject

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Date: December 21, 2005  

Models: 2000 (BR/BE) Ram Pickup

NOTE- This bulletin applies to federal emissions-certified vehicles (sales code NAA)
equipped with a 5.9L (sales code EMM) or 8.0L (sales code EWA) engine.

This Bulletin involves inspecting and if necessary replacing the catalytic converter.

NOTE: The Original Design catalytic Converter warranty has been extended to
December 30, 2006. Vehicles that according to warranty records have already
had the catalytic converter replaced with an improved service part have been
excluded from this extended warranty.

The vehicle operator may describe a rattling sound from the underside of the vehicle.

1.      Verify the vehicle is covered by the Extended Warranty.
2. If the vehicle operator describes a rattling sound from the underside of the vehicle,
perform the following "thump" test to determine if the catalyst substrate is "loose" or
"rattling" inside the can.
   a. Raise the vehicle on a hoist and with the vehicle properly secured, identify a solid
      surface on the body of the catalytic converter to strike from the underside. (Note:
      Avoid striking a heat shield as the heat shield itself may be rattling). If there is a skid
      plate in the way, choose a solid connecting pipe close to the converter body to
   b. Strike (thump) the surface identified above using a sharp blow from an appropriate
      rubber mallet.
   c. Loose ceramic cores (substrates) in converter shells have a distinct "rafting" sound
      when struck by a mallet. The sound is like a masonry brick rattling inside a metal
      can. (Note: This rattling sound is NOT a resonant sound that would be consistent
      with loose metal to metal exhaust pipe or hanger connections).
   d. Other sources of rattle noises, such as loose exhaust connections, muffler parts, or
      any other part of the exhaust system, should be eliminated by holding the
      connecting pipes and the muffler while thumping the converter. This will isolate
      potentially interfering noises.
    e. If the results of the inspection are positive, and a "rattling" noise is detected, replace
      the catalytic converter.

Parts Required: Use the catalytic converter currently listed in StarParts® for the appropriate vehicle.

Repair Procedure: 

1.   Replace the catalytic converter. Refer to the service information available in
      TechCONNECT. Reference: Service Info. 11 - Exhaust - Catalytic Converters -
      Removal and Installation.


Reimbursable within the provisions of the extended warranty period of 12 months, which
expires on December 30, 2006. This service does not include the replacement of other
exhaust system components. If other exhaust system components require replacement,
the associated repair costs are the customer's responsibility. Refer to Warranty Bulletin
D-05-26 for complete details

Time Allowance:

Labor Operation No:   Description Amount
11-50-01-92 Catalytic Converter, Inspect 0.2  Hrs.
11-50-01-93 Catalytic Converter, Inspect and Replace 1.2  Hrs.

Failure Code:

ZZ        Service Action

I would like to thank Bob Bergevin, Arthur Cantrall, Barry Drodge, David Lovell, Bill Maurits, and Steve for supplying the information for these bulletins. And a big thank you goes to Geno's Garage for making possible.


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This page was edited on: May 3, 2004