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TSB 11-006-05

Catalytic Converter Extended Warranty

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Date: December 21, 2005

Models: 1996 - 1999 (BR/BE) Ram Truck

1996 - 1997   (AB) Ram Van
1997               (AN) Dakota
1999               (AN) Dakota
1996 - 1999   (BR/BE) Ram Truck
1996               (XJ) Cherokee

NOTE: This bulletin applies to vehicles equipped as shown in the table below.

Year Model Engine and Sales Code
1996 - 1997 AB 3.9L - EHC
1997 AN 3.9L - EHC
1999 AN 3.9L - EHC
1996 BR 3.9L - EHC, 5.2L - ELF, 5.9L - EML
1997 - 1998   BR 3.9L - EHC
1999 BR/BE 5.2L - ELF
1999 XJ 2.5L - EPE

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

NOTE: The Original Design Catalytic Converter warranty has been extended to 10 years/120,000 miles, or until December 30, 2006, whichever is longer. Additionally, in states that require SMOG or I/M testing, replacement of the catalytic converter due to certain test failures will be covered as a warranty expense. 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 may have an illuminated MIL as the result of a Diagnostic Trouble Code (DTC) P0420 - Catalyst Efficiency, or may have failed a California SMOG or state I/M test but without an illuminated MIL, or 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 has a M I L illuminated as a result of Diagnostic Trouble Code (DTC)
P0420 - Catalyst Efficiency or if it has failed an I/M or SMOG check and has no MIL
illuminated, perform the Repair Procedure
3. 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 10 year/120,000
miles or until December 30, 2006, whichever is longer, or for certain I/M test failures. Refer
to Warranty Bulletin D-05-25 for complete details. 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.

Time Allowance:

Labor Operation No:   Description Amount
11-50-01-97 Catalytic Converter, Inspect 0.2  Hrs.
11-50-01-98 Inspect and Replace Catalytic Converter 1.1 Hrs.
96 - 97 AB Body
97 AN Body
99 AN Body
96 - 99 BR Body
All except 5.9L engine
0.9 Hrs.
96 XJ Body
11-50-01-99 Inspect and Replace Catalytic Converter 1.2 Hrs.
96 BR Body

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: January 3, 2007