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TSB 18-001-07

Flash: Check Gauges Lamp Illuminates For Alternator Charging
With DTC P2502, P2503, or P2509

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Date: January 06, 2007   


Models: 2007 (D1/DH) Ram Truck (2500 / 3500)

NOTE: This bulletin applies to vehicles equipped with a 5.9L engine (sales code
ETH) built on or before November 29, 2006 (MDH 1129XX).

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

The customer may experience the illumination of the "Check Gauges" lamp on the
instrument panel cluster. Inspection of the gauges may reveal that the battery charging
gauge may read in the 11 volt range rather than in the 14 volt range. There may not be a
Check Engine / Malfunction Indicator Lamp (MIL) illumination.

Further diagnosis may reveal the following Diagnostic Trouble Codes (DTC's) have been
          P2502 - Charging System Error - Diesel
          P2503 - Charging System Output Low - Diesel
          P2509 - Powerdown Data Lost Error - Diesel

Using a Scan Tool (StarSCAN) with the appropriate Diagnostic Procedures available in
TechCONNECT, 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
Repair Procedure.

NOTE: The Repair Procedure (PCM reprogramming/flash) currently can not be
performed using the StarMOBILE in its STANDALONE mode. Use the StarSCANIII
to perform the Repair Procedure, or use the StarMOBILE in its CONNECTED
mode to perform the Repair Procedure.

Parts Required:
Qty. Part No. Description
AR 04275086AB Label, Authorized Modification

Special Tools/Equipment Required:

NPN    Battery Charger
CH9401       StarSCAN® Tool
CH9404 StarSCAN® Vehicle Cable
CH9409 StarSCAN® Documentation Kit
CH9410 StarSCAN® Ethernet Cable, 12 ft.
CH9412 StarSCAN® Software Update Device Kit
  TechCONNECT PC or equivalent

Repair Procedure: 

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, 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 either:
"DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation",
or refer to the StarSCAN Quick Start Networking Guide. The StarSCAN Quick Start
Networking Guide is also available on the website under
the "Download Center".

NOTE: The Repair Procedure (PCM reprogramming/flash) currently can not be
performed using the StarMOBILE in its STANDALONE mode. Use the StarSCAN
to perform the Repair Procedure, or use the StarMOBILE, in its CONNECTED made
to perform the Repair Procedure.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.
1.      Open the hood and install a battery charger. Using a voltmeter,
verify that the charging rate provides 13.2 - 13.5 volts. Set the battery
charger to continuous charge. Do not allow the charger to time out
during the flash process. Remove the charger from the battery when
the flash process is complete.
NOTE: Do not allow the charging voltage to climb above 13.5 volts during
the flash process.
2. Obtain the vehicle Personal Identification Number (PIN). This information may be
obtained from:
a. The original selling invoice.
b. The DealerCONNECT system under the "Parts" tabs - select "Key Codes".
c. By contacting the District Manager.
3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and
the dealer's network drop.
4. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle.
5. Power ON the StarSCAN.
6. . Select "ECU View"
7. Touch the screen to highlight the appropriate ECU in the list of modules.
8. Select "More Options"
9. Select "ECU Flash"
10. Record the part number at the top of the "Flash PCM" screen for later reference.
11. Select "Browse for New File". Follow the on screen instructions.
12. Highlight the calibration then select "Download to Scantool".
13. Select "Close" after the download is complete, then select "Back".
14. Highlight the listed calibration.
15. Select "Update Controller". Follow on screen instructions.
16. When the PCM update is complete, select "OK".
17. Verify the part number at the top of the "Flash PCM" screen has updated to
the new part number.
18. The Wireless Control Module (WCM) requires updating of the Secret Key information
using the PIN information obtained earlier. From the StarScan Home Menu:
    a. Select "ECU View"
    b. Select "WCM".
    c. Select "Miscellaneous Functions"'.
    d. Select "PCM Replace".
    e. Follow the on-screen prompts to complete the updating process.
19. Once the WCM has been updated, clear all DTC'S.
NOTE: Due to the PCM programming procedure, a DTC may be set in other modules
within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate.
From the "Home" screen select "System View,". Then select "All DTCS".
Press "Clear All Stored DTCS" if there are any DTCs shown on the list.
NOTE- The following step is required by law when reprogramming a PCM and/or TCM.
20. Type the necessary information on the "Authorized Modification Label" p/n
04275086AB and attach near the VECI label (Fig. 1).




Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:

Labor Operation No:   Description Amount
18-19-04-24 Module, Engine Control (ECM) Cummins 6.9L -
Reprogram (B)
0.4 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: February 21, 2008