DodgeRam.info > TSB's > Recalls > Recall B15

Safety Recall #B15

Diesel Engine Throttle Linkage
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Date: July 2002

Models: 1997-1998 (BR/BE) Dodge Ram Truck

NOTE: This recall applies only to the above vehicles equipped with a 5.9L Cummins turbo diesel engine ("D" in the 8th VIN Position) built at the:

IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System.

Subject:

The throttle control linkage joints on about 97,500 of the above vehicles may corrode and cause the throttle to bind or stick, This could increase the truck's stopping distance and cause an accident without warning.

Repair:

The throttle linkage rod ends and linkage ball studs must be replaced.

Parts:

Quantity    Description 
2     Throttle rod ball studs
2          Throttle rod ball stud nuts
1   Short threaded rod end
1   Long threaded rod end

Each dealer to whom vehicles in the recall were invoiced will receive enough Throttle Control Linkage-Packages to service about 10% of those vehicles.

Service Procedure:

1.    Loosen the band clamps from both sides of the tube that connects the charge air cooler to the intake manifold air horn.

2.    Remove the charge air cooler-to-air horn tube from the vehicle.

3.    Unclip the engine wiring harness from the C"the cable mounting bracket.

4.    For trucks equipped with an automatic transmission, disconnect the Throttle Position Sensor (TPS) electrical connector, remove the two TPS attaching bolts and then remove the TPS (Figure 1).

5.    Disconnect the throttle cable from the primary bellcrank ball stud. To do this, place a 3/8 inch open end wrench between the primary bellcrank arm and throttle cable socket and then pry the cable socket off the ball stud (Figure 1).

6.    Apply a small amount of silicone spray lubricant to both sides of the throttle control cable rubber grommet (Figure 1).

NOTE: The throttle control cable rubber grommet is pressed into the cable mounting bracket.

7.    Work the rubber grommet on the throttle control cable rearward through the cable mounting bracket with two small screwdrivers and remove the throttle control cable from the cable mounting bracket (Figure 1).

8.    For trucks equipped with an automatic transmission, slide the plastic snap cap forward to disconnect the transmission throttle valve cable from the nail head on the secondary bellcrank.

9.    For trucks equipped with an automatic transmission, remove the throttle valve cable from the cable mounting bracket.

10.  For trucks equipped with speed control, slide the plastic snap cap forward to disconnect the speed control cable from the nail bead on the primary bellcrank.

11.  For trucks equipped with speed control, remove the speed control, cable from the cable mounting bracket.

12.  Disconnect the throttle lever return spring(s) from the throttle lever.

13.  Remove the three cable mounting bracket bolts (Figure 2).

14.  Remove the two throttle lever bolts (Figure 2).

CAUTION: Do not loosen throttle lever adjustment lock-down screw

figure 1 figure 2
Figure 1 Figure 2
 

15.  Remove the cable mounting bracket, throttle lever and control rod as an assembly (Figure 2).

16.  Support the secondary bellcrank by clamping the rod end in a vise (Figure 3).

17.  Using a flat file, file the opposite side of the secondary bellcrank throttle rod ball stud (peened side) until it is flush with the bellcrank surface (Figure 3).

18.  Using a ball peen hammer and a small punch, drive the throttle rod ball stud from the secondary bellcrank (Figure 4).

figure 3 figure 4
Figure 3 Figure 4

19.  Install a new thottle-rod ball stud as shown in Figure 5. Tighten ball stud nut to 80 in. tbs. (9 N-m).

20.  Unscrew and discard the old ball stud and retaining nut from the throttle lever (Figure 6).

21.  Install a new ball stud onto the throttle lever in the same position as the original ball stud (Figure 6). Tighten the new ball stud nut to 80 in. lbs. (9 N-m).

figure 5 figure 6
Figure 5 Figure 6

 

22.  Remove the original throttle rod ends from the throttle rod (Figure 7).

23.  Match the new throttle rod ends to the old throttle rod ends. Install the new throttle rod ends onto the original throttle rod. The rod end openings must be oriented as shown in Figure 7.

24.  Tighten the secondary bellcrank rod end lock nut to 80 in. lbs. (9 N-m) (Figure 7).

figure 7
Figure 7

25.  Install that throttle control rod end onto the secondary bellcrank ball stud.

CAUTION: Do not apply any type of lubricant (grease, oil, silicone spray, etc.) to any of the ball studs or throttle rod ends.

26.  Install the other end of the throttle rod onto the throttle lever ball stud.

NOTE: The throttle rod length adjustment screw must be on the throttle lever side of the throttle rod (rear of vehicle).

27.  Install the throttle control bracket, throttle rod and throttle lever onto the engine as an assembly (Figure 2).

28.  Tighten the three cable mounting bracket bolts to 18 fl. lbs. (24 N-m) (Figure 2).

29.  Tighten the two throttle lever bolts to 80 in. lbs. (9 N-m) (Figure 2).

30.  Install the throttle lever return spring(s) onto the throttle lever.

31.  For trucks equipped with speed control, install the speed control cable into the cable mounting bracket.

32.  For trucks equipped with speed control, attach the speed control cable by sliding the end of the cable onto the nail head on the primary bellcrank lever and snap it into place.

33.  For trucks equipped with an automatic transmission, install the throttle valve cable into the cable mounting bracket (Figure 1).

34.  For trucks equipped with in automatic transmission, slide the transmission throttle valve cable end onto than nail head stud on the secondary bellcrank lever and snap it into place.

35.  Install the throttle control cable through the cable mounting bracket until the rubber grommet looks into position (Figure 1).

36.  Measure the distance between the center of the primary bellcrank ball stud and the rear face of the cable mounting bracket (Figure 8). If it is five (5) inches (126.5 mm) continue with Step 39. If the throttle rod is out of specifications, adjust it as follows:

NOTE: To prevent damage to the ends of the linkage, attach locking-type pliers to the flat located on the linkage screw before loosening the lock nuts.

a. Loosen the right-hand-threaded lock nut.

b. Loosen the left-hand-threaded lock nut.

c. Rotate the throttle rod length adjust screw (lengthen or shorten as required) to achieve proper linkage measurement.

d. Tighten both lock nuts to 80 in. lbs. (9 N-.m) after making the throttle rod adjustment.


Figure 8

37.  Position the throttle control cable end over the ball stud on the primary bellcrank lever and then snap it into place.

38.  Check the throttle linkage for Wide Open Throttle (WOT) as follows:

a. With the key in the OFF position, leave an assistant push and hold the accelerator pedal to WOT position.

b. While in the WOT position, pull forward on the throttle lever. There should be no movement of the throttle lever and it should be in its full forward position.

c. If the throttle lever is not in the full forward position, adjust the throttle rod length to achieve WOT.

39.  For trucks equipped with an automatic transmission, install the Throttle Position Sensor (TPS) and tighten the two mounting screws. Then connect the TPS electrical connector (Figure 1).

NOTE: The TPS is spring loaded. After positioning the TPS on the mounting bracket, rotate the TPS counterclockwise until both mounting holes align.

40.  Adjust the TPS using the following procedure:

> 1997 Model Year Trucks:

NOTE: The DRB III will require a Super Card 2 to check the TPS.

a. Connect the DRB III to the diagnostic connector located under the instrument panel near the steering column.

b. Turn the ignition switch to the "RUN" position. Do not start the engine.

c. Select "DRB STANDALONE" on the DRB III and press enter.

d. Select "1983 - 1997 DIAGNOSTICS" and press enter.

e. Select "1994 - 1997 DIAGNOSTICS" and press enter.

f. Select "1994 - 1997 DIAGNOSTICS" and press enter.

g. Select "ENGINE" and press enter.

h. Select "SENSOR DISPLAY" and press enter.

i. The voltage at the TPS should be 1.0 volt (+ 0.2 volts) with the linkage in the idle position. At Wide Open Throttle (WOT), the output voltage of the TPS must be 2.2-to-2.9 volts higher than at idle speed. If voltage is not correct, recheck the linkage adjustment.

CAUTION: Do not lengthen or shorten the linkage rod more than 3/64 inch (1 mm) from the dimension shown in Figure 8.

> 1998 Model Year Trucks:

a. Connect the DRB III to the diagnostic connector located under the instrument panel near the steering column.

b. Turn the ignition switch to the "RUN" position. Do not start the engine.

c. Select "DRB STANDALONE" on the DRB III and press enter.

d. Select "1998 - 2003 DIAGNOSTICS" and press enter.

e. Select "ALL (EXCEPT BELOW)" and press enter.

f. Select "SENSOR DISPLAY" and press enter.

h. The voltage at the TPS should be 1.0 volt (+ 0.2 volts) with the linkage in the idle position. At Wide Open Throttle (WOT), the output voltage of the TPS must be 2.2-to-2.9 volts higher than at idle speed. If voltage is not correct, recheck the linkage adjustment.

CAUTION: Do not lengthen or shorten the linkage rod more than 3/64 inch (1 mm) from the dimension shown in Figure 8.

41.  Install the charge air cooler-to-air horn tube. Position the band clamps and tighten to 95 in. lbs. (11 N-m).

42  Start the engine and verify proper throttle operation.

Completion Reporting and Reimbursement

Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments.

Use one of the following labor operation number and time allowance:

   Labor Operation Number   Time Allowance 
Replace throttle linkage
(with automatic transmission)    
14-B1-51-82 1.2 hours
Replace throttle linkage
(with manual transmission)  
14-B1-51-83 1.1 hours

Add the cost of the part plus applicable dealer allowance to your claim.

NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

Parts Return: Not required.

Owner Notification and Service Scheduling

All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers.

Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.

Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair.


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 DodgeRam.info possible.

 

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This page was edited on: May 3, 2004