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TSB 03-001-07

4WD System May Not Engage Or Disengage As Desired With "SERV 4WD" Message

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Date: July 21, 2007  

THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.

Models: 2006 - 2007 (DR) Ram Truck (1500)

NOTE: This bulletin applies to light duty 4x4 Ram Trucks built on or before June 01, 2007 (MDH 0601XX).

Overview:
This bulletin involves replacement of the Front Axle Disconnect (FAD) actuator and
selectively erasing and reprogramming the Totally Integrated Power Module (TIPM) with new software.

Symptom/Condition:
The vehicle operator may experience one or more of the following conditions:

A). The four wheel drive (4WD) system may not engage or disengage as designed, when the drive mode is changed between 2WD and either 4WD Auto or 4WD Lock (or back to 2WD from 4WD).

B). An illumination of the "SERV 4WD" message in the Instrument Panel (IP)

C). When four wheel drive (4WD) mode is selected, the amber "4WD" lamp flashes
continuously in the IP signaling that the 4WD system has not been engaged.

D). Diagnostic Trouble Code (DTC) C1464 - Front Axle Disconnect (FAD) High Side Short To Ground - is present in the TIPM.

This condition may be due to TIPM software and its affect on the FAD actuator mechanism.

Diagnosis:
1. Set vehicle parking brake. Start vehicle engine and allow to idle.
2. From the StarSCAN Main menu select:
    a. ECU View.
    b. TIPM CGW
    c. Data Display.
    d. Front Axle Disconnect.
    e. Monitor the FAD state: "OFF" or "ON".
3. When the transfer case and FAD are in 2WD mode, the StarSCAN should display an "OFF" reading (state).
    When the transfer case and FAD are in 4WD mode, the StarSCAN should display an "ON" reading (state).

NOTE: The vehicle may need to be moved a small distance to allow FAD and transfer case engagement and disengagement.

4. Cycle the 4WD Control Switch (Transfer Case Switch) from 2WD mode to 4WD mode and back.
    Monitor the FAD state (ON or OFF) as the 4WD Control Switch is moved from one mode to the other mode.
5. Does the FAD state change as it should when the 4WD Control Switch is moved from 2WD mode to 4WD mode and back?
    a. If YES ==> then proceed to the next step.
    b. If NO ==> then perform the Repair Procedure.
6. Is the "SERV 4WD" lamp illuminated and does it remain on?
    a. If YES ==> then proceed to the next step.
    b. If NO ==> then STOP. Further diagnosis is required.
7. Is DTCC 1464 - Front Axle Disconnect (FAD) High Side Short To Ground - present in the TIPM?
    a. If YES ==> then perform the Repair Procedure.
    b. If NO ==> then STOP, Further diagnosis is required.
8. Stop the vehicle engine. Turn the ignition switch to the "OFF" position.

Parts Required:

Qty.	Part No.	Description
1	52114387AE	Actuator, Front Axle Disconnect (includes: gasket and pads)
(AR) 1	05010320AA	Synthetic Gear Lubricant - SAE 75W90 GL-5 (MS-9763)

Special Tools/Equipment Required:

Repair Procedure: 

A). FRONT AXLE DISCONNECT ACTUATOR - REPLACE

1.	Raise the vehicle on a frame lift.
2.	Remove the FAD actuator wiring connector
3.	Remove the four (4) actuator bolts (Fig. 1).
	1 - Front Axle Disconnect (FAD) Actuator 2 - Front Axis And Disconnect Pocket
4.	Remove the FAD actuator from the axle disconnect pocket.
NOTE: Inspect the disconnect sleeve, and the output and intermediate axle shaft disconnect gears for damage (chipped or worn). Repair as required. Replacement of the disconnect sleeve, and output or intermediate axle shaft disconnect gears is not addressed by this Service Bulletin.
5.	Clean the FAD actuator sealing surface.
6.	Verify that the actuator shift fork pads are properly installed.
7.	Align the FAD actuator shift fork with the disconnect collar and install the FAD actuator on the axle disconnect pocket.
8.	Hand start the four (4) FAD actuator bolts. Tighten bolts in a diagonal pattern to 30 Nm (22 ft. lbs.).
9.	Install the FAD actuator wiring connector.
10.	Verify front axle fluid level.
11.	Lower vehicle.
12.	Verify proper operation of the FAD actuator.
13.	Turn the 'ignition switch to the "OFF" position.
14.	Proceed to the next section - Reprogram TIPM.

B). REPROGRAM TIPM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE:

NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the
StarSCAN screen.

NOTE: The StarSCAN diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN for your dealership's network. For instruction on setting up your StarSCAN for the dealer's network; refer to the StarSCAN Quick Start Networking Guide available on the www.dcctools.com website under the "download center".

NOTE. If this flash process is interrupted/aborted, the flash should be restarted.

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:

Failure Code:

This page was edited on: July 26, 2007