TSB's for 2002 trucks
Category 2 - Front Suspension
Toe-in specification change.
02-This bulletin involves an update to the toe-in specification for front end 003-All alignments. The specification for toe-in has been revised to 0.2? +- 0.1? total
02 toe in. This change has been shown to improve straight ahead driving
performance and should be used whenever a front end alignment is performed.
Category 3 - Rear Axle
Front axle disconnect system.
This bulletin involves a mid-2002 model year deletion of the front axle
disconnect system on 2002 (BE/BR) 2500 and 3500 Ram Trucks. This change
effects the front axle, transfer case and engine/headlamp and dash wiring
harnesses. The bulletin applies to 2500 and 3500 (BE/BR) Ram trucks built
03-after January 4, 2002 and equipped with front axles with the following part
001-All numbers: 52070136AO, 52070137AO, 52070138AP, and 52070139AO.
The vehicles involved will retain Shift On the Fly (SFO) capability; however,
with this change, the front driveshaft will now turn continuously when the
vehicle is being driven. Due to the timing of this change this information is not
reflected in the Service Manual and a future release will outline service
Use of synthetic rear axle lubricant.
This bulletin applies to 2002-2003 (DR) Ram trucks equipped with the 9 1/4"
rear axle and trailer tow package. It is critical to optimum performance in 03-trailer towing conditions that when service is being performed on the 9 1/4" 002-All rear axle on 2002-2003 (DR) Ram trucks, the axle must be refilled with Mopar 02 75W-140 synthetic gear and axle lubricant (PN 04874469). Five ounces
(148ml) of Mopar friction modifier (PN 04318060AB) must also be added to
vehicles equipped with the trac-lok style rear axle.
Category 5 - Brakes
Category 6 - Clutch
Category 7 - Cooling
Category 8 - Electrical
Airbag/clock spring service.
When servicing any airbag system, it is essential to follow the proper Service
Manual and/or Diagnostic Manual procedures for diagnosing, testing, and
replacing of any component. Do not use silicone or any other lubricant spray 08-on or near the clock spring. Lubricants are often used in the clock spring area 010-All of the steering column to eliminate noise. Any repair that may disrupt the 01 positioning of the steering wheel with the front wheels will require that the
clock spring be centered. This includes clock spring replacement, steering
column service, HVAC service, steering gear service, and front suspension
Horn chirp and erroneous alarm. 08-This bulletin involves reprogramming the forward control module (FCM) 016-All should there be an erroneous horn chirp when a door is opened or an erroneous 02 alarm. The correction is a reflash of the FCM.
Electro mechanical instrument cluster (MIC) erroneous indicator lamps.
Three conditions have been identified which may be caused by communication
errors between the electro mechanical instrument cluster (MIC) and other
electronic modules on the vehicle. 1. An intermittent false “Check Gauges” on 08-diesel engine equipped vehicles. 2. An intermittent false chime and “Low 004-All Wash” indicator. 3. A “Trans Temp” indicator on a manual transmissions 03 equipped vehicle.
This bulletin involves selectively erasing and reprogramming the MIC with
08-Radio communication equipment installation recommendations. 024-All This information only bulletin gives the dealership technician some guidelines
05 for the installation of two-way radio equipment.
Category 9 - Engine
Engine oil additives/supplements.
(EOS) should not be used to enhance engine oil performance. Engine oil
additives/supplements should not be used to extend engine oil change
09-intervals. No additive is known to be safe for engine durability and can
003-All degrade emission components. Additives can contain undesirable materials
01 that harm the long term durability of engines. Generally it is not desirable to
mix additive packages from different suppliers in the crankcase; there have
been reports of low temperature of low temperature engine failures caused by
additive package incompatibility with such mixtures.
Engine Oil Pan Gasket Sealing
This bulletin applies to Ram trucks equipped with the 24-valve diesel engine.
Repeated oil pan gasket leaks can occur on 24-valve diesels if the gasket is 09-applied without the use of Mopar Silicon Rubber Adhesive (RTV) Sealant (PN
006-All 04883971). This bulletin provides routing of the sealant when replacing the
01 engine oil pan gasket. When replacing an oil pan gasket, apply a 1/8" bead of
RTV to the oil pan side of the gasket , around the back of the engine,
extending up to the fourth bolt hole from the rear on each side, as per the
Crankcase Breather Overflow
This bulletin applies to 1998-2002 (BR) Ram trucks equipped with the 24-
valve Cummins diesel engine built after March 27, 1998 (engine serial number
56443872). Owners of these vehicles may experience engine oil overflow from
09-the front crankcase breather when the vehicle is operated off-road on an 002-All extreme downhill grade (37.5% or 22? slope/grade). Operation of this type for
02 extended periods of time can cause enough engine oil depletion to damage the
engine. A kit containing all components necessary to eliminate the oil
overflow has been made available. If the condition exists, perform the repair
procedure outlined in this bulletin. The repair involves the addition of a new
Engine knock or rattle sound when climbing a long grade and towing a heavy
This bulletin applies to 1998-2002 Ram trucks equipped with the 24-valve 09-Cummins diesel engine (sales code ETC or ETH). Owners may experience an
008-All engine knock or rattle sound when climbing a long grade while towing a heavy
02 trailer. If the condition exists, replace the engine thermostat as outlined in the
service manual. Note: Mopar 05015708AC is to be used exclusively for this
service bulletin. Use thermostat 05015708AB for all other 24-vlave Cummins
Category 11 - Exhaust
Category 14 - Fuel
14-Fuel cap difficult to remove. 001-All This bulletin involves installing a revised fuel cap. 02 A
Tampering with VP44 fuel pump on Cummins diesel engine. 14-This bulletin supersedes technical service bulletin 14-002-02, dated July 1, 002-All 2002. A number of the VP44 fuel pumps have been returned through the
02 A warranty process as a result of tampering. Generally, the customer complains
that the vehicle dies while driving. When diagnosed, there may or may not be
Diagnostic Trouble Codes (DTC) present. When DTCs are present, there may
be one or more of the following:
P DTC Description Code
124 P 0234 Turbo boost limit exceeded.
Decreased engine performance due to engine overheat 146 P 0217 condition.
361 P 0254 Fuel injection pump fuel valve current too high.
Fuel injection pump mechanical failure fuel valve feedback 363 P 0251 circuit.
364 P 1689 No communication between ECM and injector pump module.
375 P 0602 ECM fuel calibration error.
The diagrams show the area where performance enhancing equipment is being connected into the outboard wire of the two wires that control operation of the
metering solenoid in the pump. Another type of device places a connector
between the metering solenoid harness and the upper connector on the pump.
Telltale evidence can be seizure of the pump rotor, and/or cracked or
overstressed pump cam ring. The protective sleeve around the two wires may
be rolled or cut back to gain access for connection. Injection pumps that have
been tampered with are not warrantable.
Category 16 - Propeller Shafts & U-joints
Category 18 - Vehicle Performance
Performance enhancement for severe cold weather environments.
This bulletin applies to all Ram trucks equipped with a 5.9L 24-valve
Cummins diesel engine with a 49-state emissions calibration and an
automatic transmission. The bulletin describes how to selectively erase
and reprogram the Powertrain Control Model (PCM) with new software
(59t7a). The problem addressed by the PCM reprogram is a hard starting
18-and/or idle speed fluctuations condtion.
01 Cummins 24-vavle engines used with automatic transmissions can be
severely affected by the use of sub-grade #1 diesel fuel when ambient
temperatures are below 0?C (32?F), typically prevalent during the Winter
months in Alaska, Northwestern Canada, and similar
This change will have no effect on performance during warm weather or
when standard grade diesel fuels #1 or #2 are used.
Vehicles with 49-state certification can apply this calibration if needed. The calibration can be changed back to the original calibration if desired. Cold idle engine warming.
This bulletin involves selectively erasing and reprogramming the Engine
Control Module with new software. This bulletin applies to all Ram
trucks built after December 17, 1997 equipped with the 24-valve 5.9L Cummins diesel engine.
Extended idle operation, especially in cold weather, can allow
varnishes/oils to condense on the exhaust valve stems, leading to stuck
valves, and damaged valve train components. The repair procedure
involves calibration software that will activate when certain parameters
are met, reducing the chance of valve sticking as well as improving cab
heat warm-up time. Idle speed will slowly ramp up from 800 rpm to 1200 rpm when all of the following conditions are met: * Intake Manifold Temperature less than 60?C (32?F) * Coolant Temp is less than 60?C (140?F) 18-All 24v * The transmission is in Neutral or Park 019-engines * The Service Brake pedal is not depressed 01 * Throttle = 0%
* Vehicle Speed = 0 mph
If intake manifold temperature (IMT) is less than -9?C (15?F), three of the cylinders will be shut off upon reaching 1200 rpm, creating a slight
change in engine sound which is normal. Thus the engine has to work to
overcome the three “dead” cylinders. This allows the engine to create
increased heat in the cooling system, allowing more rapid warm up.
Either feature will abort when any one of the following occurs: * The automatic transmission is placed in gear (forward or reverse) * The service brake pedal is depressed
* Throttle position is greater than 0%
* Vehicle speed greater than 0 mph
* Coolant temperature is greater than 79?C (175?F)
Generic Cummins engine control module (ECM) procedure. This bulletin applies to Ram trucks equipped with the 5.9L Cummins 24-
18-valve diesel engine (sales code ETC or ETH). Mopar is phasing out pre-
030-All programmed Cummins Diesel engine control modules (ECM). New
03 modules will no longer be pre-programmed when received from Mopar.
Replacement of future ECM’s will require programming utilizing the
DRBIII and TechCONNECT.
18-Generic Cummins engine control module (ECM) procedure. All 030-This bulletin applies to Ram trucks equipped with the 5.9L Cummins 24-
03 valve diesel engine (sales code ETC or ETH). Mopar is phasing out pre-
programmed Cummins Diesel engine control modules (ECM). New
modules will no longer be pre-programmed when received from Mopar.
Replacement of future ECM’s will require programming utilizing the
DRBIII and TechCONNECT.
Cummins engine control module (ECM) procedure.
Mopar is phasing out pre-programmed Cummins diesel engine control 18-modules (ECM). New modules will no longer be pre-programmed when 033-All received from Mopar. Replacement of future ECM's will require 04 programming at the dealership. This bulletin describes the programming
Category 19 - Steering
Driver airbag trim cover service.
Driver airbag trim cover/horn switches for the above vehicles are serviceable
and as such when applicable, must be used instead of replacing the airbag
module assembly. Airbag module assemblies returned for trim cover and
19-serviceable horn switch issues, are subject to charge back.
01 The horn switch is integral to the driver airbag unit. Only DaimlerChrysler-
trained and authorized dealer service technicians should perform service of
this unit. Failure to take the proper precautions or to follow the proper
procedures could result in accidental, incomplete, or improper airbag
deployment and possible occupant injuries.
Hissing sound coming from the power steering system on vehicles equipped
with hydroboost brakes. 19-A hissing sound may be present in the power steering system during steering 003-All maneuvers or straight ahead driving. This bulletin involves replacing the 02 power steering hoses connecting the hydroboost to the power steering pump
Power steering fluid usage.
The factory fill power steering fluid for most 2004 model year Chrysler Group
vehicles is ATF+4 (part number 05013457AA/S9602) and it provides superior
performance at both low and high temperatures. Refer to the table to identify 19-factory fill and the approved service power steering fluid by year and model. 005-All From the table it is noted that the ’94 to ’02 truck uses part number 03 04883077/MS5931.
MS9602 should not be mixed or used as a "topping off" fluid on systems
19-Power steering fluid usage.
005-All The factory fill power steering fluid for most 2004 model year Chrysler Group
03 vehicles is ATF+4 (part number 05013457AA/S9602) and it provides superior
performance at both low and high temperatures. Refer to the table to identify
factory fill and the approved service power steering fluid by year and model.
From the table it is noted that the ’94 to ’02 truck uses part number 04883077/MS5931.
MS9602 should not be mixed or used as a “topping off” fluid on systems
Revised power steering system bleeding procedures. This bulletin supersedes service bulletin 19-008-05, dated October 26, 2005. The bulletin discussed that Mopar Power Steering fl uid +4 or ATF+4 (MS-19-9602) is to be used in the power steering system of DR vehicles. No other 008-All power steering or automatic transmission fl uid is to be used in these systems. 05 Damage may result to the power steering pump and system if the incorrect fl
uid is used. Do not overfill the power steering reservoir. If the air is not purged
from the power steering system correctly, pump failure could result.
Category 21 - Transmission Automatic transmission fluid usage ATF+4 (Type 9602). This information only bulletin supersedes technical service bulletin 21-16-
99, date October 22, 1999. The bulletin discusses a new transmission fluid
(ATF+4 - Type 9602) which has been developed and is being used as factory fill for all vehicles with Chrysler automatic transmissions. Until
now, vehicles originally filled with ATF+2 or ATF+3 were to be serviced
with ATF+3. Effective immediately, it is recommended that all vehicles
with Chrysler automatic transmissions except for 1999 and earlier minivans
be serviced with ATF+4. ATF+3 should continue to be used for 1999 and
earlier minivans because of the potential for torque converter shudder
during break in. For all other applications the ATF+4 fluid offers significant benefits as outlined below.
21-Auto 006-ATF+4 must always be used in vehicles that were originally filled with trans ATF+4. 01
Service intervals do not change. The service interval currently in effect for a
given vehicle should continue to be followed.
ATF+4 is compatible with ATF+3 and can be used to top off vehicles that
currently have ATF+2 or ATF+3. Do not use ATF+2 or ATF+3 to top off
vehicles that have ATF+4 fluid.
? Better wear properties
? Improved rust/corrosion prevention
? Controls oxidation
? Eliminates deposits
? Controls friction
? Retains anti-foaming properties
? Superior properties for low temperature operation
Mopar ATF+4 is a World Class Fluid having exceptional durability.
However, the red dye used in ATF+4 is not permanent; as the fluid ages it
may become darker or appear brown in color. ATF+4 also has a unique
odor that may change with age. With ATF+4 fluid, color and odor are no
longer indicators of fluid condition and do not support a fluid change. 21-Automatic transmission diagnostic teardown procedure. 009-All This bulletin provides a procedure to determine repair versus replacement of
03 an automatic transmission assembly.
Automatic transmission fl uid usage ATF+4 (Type MS9602).
This bulletin supersedes technical service bulletin 21-004-04, dated March
16, 2004. ATF+4, type 9602, is being used as factory fi ll for Chrysler
Group automatic transmissions. ATF+4 is recommended for all vehicles
equipped with Chrysler Group automatic transmissions except for those
noted: AW-4 transmissions, Sprinter transmissions, Crossfi re
transmissions, MK/PM vehicles equipped with Continuously Variable
Transmission (CVT). ATF+4 is backward compatible with ATF+3, ATF+2,
and ATF+. Additionally, ATF+4 can be used to top off vehicles that used
ATF+3, ATF+2, or ATF+. Benefi ts:
21-? Better anti-wear properties 010-Auto ? Improved rust/corrosion prevention 06 ? Control of oxidation.
? Elimination of deposits
? Control of friction
? Retaining anti-foaming properties
? Superior properties for low temperature operation
Mopar ATF+4 has exceptional durability. However, the red dye used in
ATF+4 is not permanent; as the fl uid ages it may become darker or appear
brown in color. ATF+4 also has a unique odor that may change with age.
With ATF+4 fl uid, color and odor are no longer indicators of fl uid
condition and do not necessarily support a fl uid change.
Automatic transmission diagnostic tear down procedure.
This bulletin provides a procedure to determine repair versus replacement of
21-an automatic transmission assembly. Follow the proper repair procedure
003-All based on the transmission type. This procedure is to be used after the
07 transmission has been removed from the vehicle.
This bulletin supersedes technical service bulletin 21-008-06, dated
Category 22 - Wheels & Tires
Chrome wheel care.
This information-only bulletin discusses chrome wheel care. Chrome wheels
should be cleaned regularly with mild soap and water or Mopar Car Wash
Concentrate to maintain their luster and prevent corrosion. Wash them with the
same soap solution as the body of the vehicle. Care must be taken in the
selection of tire and wheel cleaning chemicals and equipment to prevent
damage to wheels. Any of the “Do Not Use” items listed below can damage or 22-stain wheels and wheel trim. 001-All
05 ? Wheel cleaners that contain hydrofluoric acid, bifl ouride compounds,
sulfuric acid, or phosphoric acid.
? Any abrasive type cleaner.
? Any abrasive cleaning pad (such as steel wool) or abrasive brush.
? Any oven cleaner.
? A car wash that has carbide tipped wheel-cleaning brushes.
Category 23 - Body
Equipped Outside rearview mirror glass replacement.
with This bulletin supercedes technical service bulletin 23-034-00 Rev. A 23-6x9 dated December 15, 2000. It is unnecessary to replace the entire outside
027-Mirrors rearview mirror assembly when the mirror glass is broken or is
01 Sales missing. Replacement mirror glasses are available from Mopar.
Code GPS Because of the extremely long list of part numbers involved, please
or GPU consult the Mopar parts catalog for the correct part number(s).
Water leak at grab handle.
23-Water may enter the vehicle through the secondary door seal retainer or
003-All the roof seam, onto the headliner and run down the “A” pillar, coming
04 out at the grab handle. The repair involves sealing holes in the roof
Windshield wiper blade maintenance.
Windshield wiper blades/elements are frequently replaced
unnecessarily. If the wipe pattern appears to be streaky or if there is
23-chatter and no damage to the wiper blades/elements is obvious, the
following steps should be performed: 014-All
? Use a soft cloth or sponge and squeegee and a solution of 50/50
alcohol and water, to wash the windshield.
? Raise the wiper blades off the glass and clean the wiper blade
elements with a solution of 50/50 alcohol and water and a soft
cloth, paper towel or sponge.
? Return the wiper blades to their normal operating position. If
the wipe pattern is still objectionable, repeat several times. If
the wipe pattern is still objectionable, replace the wiper
Category 24 - Air Conditioning All Chrysler
group A/C system leak detection. 24-products Vehicles from the factory no longer have leak detection dye in the 009-using R-A/C system. To determine the source of a R-134a leak, a leak tracer 02 134A dye has to be injected into the A/C system. refrigerent
A/C system additives.
The use of A/C system sealers may result in damage to A/C
refrigerant recovery/evacuation/recharging equipment and/or A/C
system components. Many federal, state/provincial and local
24-All Chrysler regulations prohibit the recharge of A/C systems with known leaks.
003-group DaimlerChrysler recommends the detection of A/C system leaks
03 products through the use of approved leak detectors available through
Pentastar Service Equipment (PSE) and fluorescent leak detection
dyes available through Mopar Parts. Vehicles found with A/C system
sealers should be treated as contaminated and replacement of the
entire A/C refrigerant system is recommended.
A/C cooling coil odor.
This bulletin involves inspecting for leaves and other foreign
material, cleaning, and treating the cooling coil and housing. Some
vehicle operators may experience a musty odor from the A/C system, 24-primarily at start up in hot and humid climates. This odor may be the 006-All result of microbial growth on the cooling coil. During normal A/C 06 system operation, condensation, bacteria and fungi growth begins and
odor results. If the operator describes, or the technician experiences a
musty odor when operating the A/C system, perform the appropriate
repair procedure based on the vehicle model.
Category 25 - Emissions
Category 26 - Miscellaneous