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TSB 21-006-07

Flash: New 48RE Feature That Allows Normal Shift Schedule
With Full Disable Of 4th Gear Overdrive

Visit Geno's Garage for Truck accessories.

Date: March 20, 2007

THE DRBIII FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT.

Models: 2005 (DH) Ram Truck (2500/3500)

NOTE: This bulletin applies to vehicles equipped with a 5.9L Cummins turbo-diesel engine
and a 48RE automatic transmission (sales codes ETH and DGB respectively).

Overview:
This bulletin involves selectively erasing and reprogramming the Cummins Engine Control
Module (ECM) with new software.

Symptom/Condition:
1. The following enhancement is included with this software:
    a. A new 48RE transmission feature that will allow normal shift schedule with full
        disable of 4th gear (overdrive gear), when the customer selects the Over-Drive
       (O/D) switch.

Prior to the implementation of this new transmission feature, the use of the O/D switch
changed the automatic transmission shift schedule from a "normal" shift schedule to a
tow/haul mode shift schedule, and allowed 4th gear (overdrive gear) engagement

This new transmission feature will not change the transmission shift schedule, but will
allow full 4th gear overdrive disable (lock out). With this new feature the customer
will have the "normal' shift schedule with NO overdrive (4th gear).

NOTE: To enable the new 4th gear disable feature, the ECM must first be
reprogrammed (flashed) with the latest software level, and then the 4th gear disable
feature "O/D OFF ENABLE" must be selected (turned on) using the DRBIII.

Tow/haul mode is not an available feature whenever the DRBIII has enabled the "O/D OFF ENABLE" selection.

Diagnosis:
Using a Scan Tool (DRBIII) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's 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.

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: 

REPAIR PROCEDURE - USING DRBIII TO RETRIEVE THE FLASH FILE FROM DealerCONNECT:

NOTE: To enable the new 4th gear disable feature, the ECM must first be reprogrammed (flashed) with the latest software level, and then the 4th gear disable feature "O/D OFF ENABLE" must be selected (turned on) using the DRBIII.

NOTE: Whenever a controller is programmed, the software in the DRBIII®; must be
programmed with the latest revision level available. Current DRBIII revision level is 63.3.

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

NOTE- Remove any unnecessary PCMCIA cards prior to starting a DRBIII flash.

1.	Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII memory. To clear the memory from the MAIN MENU power up the DRBIII and then: a. Simultaneously press the "MORE"' and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII reboots to the MAIN MENU, proceed to Step #2
2.	With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBI II select: a. "DRBIII Standalone" b. "l998 - 2007 Diagnostics" c. "All (Except Below)" d. "Engine" e. On 1998 1/2 - 2003 vehicles, select "Cummins". 2004 and later vehicles, proceed to next step. f. "Module Display" g. Record the "PCM part #" on the repair order for later reference.
NOTE. If the ECM is not operational, the "ECM part number", can be obtained from the label on the controller. For 1998 1/2 - 2002 vehicles, if the label on the controller is not legible, proceed to next step. For 2003 and later vehicles, If the label on the controller is not legible, record the "Reference No." for use later. The "Reference No." Is located in the Reference No. box at the top, center of the Engine Data Plate (Fig. 1). Do not use the reference number shown in the figure. The Engine Data Plate is located on the intake side of the breather cover or affixed to the APPS bracket.
	FIGURE 1 - ENGINE DATA PLATE 1– ENGINE SERIAL NUMBER 2– REFERENCE NUMBER 3– DATE OF ENGINE MANUFACTURE
3.	Page back to the "Main Menu"
4.	Determine if the vehicle is equipped with SKIM. Using the DRBIII select: a. "DRBIII Standalone" b. "1998 - 2007 Diagnostics c. "All" d. "System Monitor" e. "JI850 Module Scan" f. Look for "SKIM" in the list of modules.
5.	If the vehicle is not equipped with SKIM then proceed to Step #6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with Step #6. This information is available from: a. The original selling invoice. b. The DealerCONNECT system under the "Parts" tabs - select "Key Codes". c. By contacting the District Manager.
CAUTION: Failure to install the SKIM pin number into the module after flashing the Cummins ECM will cause a start and stall condition.
6.	Install a battery charger and verify that the charging rate provides approximately 13.2 - 13.8 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.
7.	If the old "ECM part number"' is known, or for 2003 and later vehicles, proceed to Step #14. On 1998 1/2 - 2002 vehicles, if the old "ECM part number" is not known, proceed to next step.
8.	On DealerCONNECT select the "Service"' tab.
9.	Select "Vehicle Information Plus"'.
10.	Select "Single VIN Inquiry".
11.	Manually enter the VIN and mileage and select "Enter".
12.	Select the "Vehicle Option" tab.
13.	Under the "Vehicle Option"' window, identify and record: a. Engine (sales code and description). b. Emissions (Federal or California) c. Transmission (Automatic, 5-speed manual, etc.).
NOTE: When reprogramming a Cummins ECM be sure to do the following: Download the flash file from TechCONNECT to the DRBIII with the DRBIII disconnected from the vehicle. Download the flash file from the DRBIII to the vehicle with the DRBIII disconnected from TechCONNECT.
14.	Connect the DRBIII to TechCONNECT. Open TechTOOLS and verify that the "DRBIII Status: Connected" message is in the upper right comer of the TechTOOLS screen.
15.	Enter the old Cummins "ECM part number" obtained from the DRBIII in Step #2 into the "Parts Criteria" window.
16.	Select "Show Updates".
17.	Highlight the proper flash file from the list: a. If the old "ECM part number" is known, highlight the flash file listed, based on the     old "ECM part number" recorded earlier Step #2. b. For 1998 1/2 - 2002, if the old OECM part number" is not known, highlight     the proper flash file based on the information that was recorded from "Vehicle Options"'     Step #13. c. For 2003 and later, if the old part number is not known, highlight the proper flash file     based on the Reference No. located in the "Ref. No." box, at the top, center of the     Engine Data Plate (Fig. 1).
18.	Select the DRBII radio button which is next to the "Download/Update" button.
19.	Select the "Download/Update" button.
20.	Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash is complete,  proceed to the next step.
21.	Disconnect the DRBIII from TechCONNECT.
22.	Connect the DRBIII to the vehicle.
23.	Download the flash from the DRBIII to the vehicle PCM. Using the DRBIII select: a. "Vehicle Flash" b. Follow the directions on the DRBIII screen. When the PGM flash process is complete,     proceed to the next step.
24.	If the vehicle is equipped with SKIM, proceed to step #25. If the vehicle is not equipped with SKIM, proceed to step #26.
25.	On vehicles equipped with SKIM, transfer the VIN and Security Key information from the SKIM to the ECM. Using the DRBIII, select: a. "DRBIII Standalone" b. "1998 - 2007 Diagnostics" c. "All" d. "Theft Alarm" e. "SKIM" f.  "Miscellaneous" g. "Cummins ECM Replaced" h.  Follow the directions on the DRBIII screen. When the PGM flash process is complete,      proceed to step #27.
26.	On vehicles not equipped with SKIM, manually enter the VIN in the ECM. Using the DRBIII, select: a. "DRBIII Standalone" b. "1998 - 2007 Diagnostics c. "All" d. "Cummins controller (ECM/ENGINE)" f.  "Miscellaneous" g. "CM84X Check VIN" h.  Follow the directions on the DRBIII screen. When the PGM flash process is complete,      proceed to the next step.
NOTE: Due to the Cummins Controller 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. 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.
27.	Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2).
	FIGURE 2 - AUTHORIZED MODIFICATION LABEL 1 - ENGINE CONTROL MODULE P/N (INSERT P/N) USED 2 - CHANGE AUTHORITY: TSB XX-XXX-XX 3 - DEALER CODE: XXXXX 4 - DATE: XX-XX-XX
NOTE: To enable the new 4th gear disable feature, the ECM must first be reprogrammed (flashed) with the latest software level, and the 4th gear disable feature "O/D OFF ENABLE" must be selected (turned on) using the DRBIII.
28.	To enable the "O/D OFF ENABLE" feature with the DRBIII. From the DRBIII Main Menu select" a.  "DRBIII Standalone" b.  "1998 - 2007 Diagnostics" c.  "All" d.  "Engine" e.  "Cummins Controller (ECM/ENGINE)" f.  "O/D OFF ENABLE"

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:

Failure Code:

This page was edited on: February 20, 2008