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2002_tsb

By Amy Bell,2014-06-17 10:00
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CHRYSLER OBD System

    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.

    02

    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

    procedures.

    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

    crossmember service.

    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

    new software.

    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

    referenced diagram.

    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

    breather kit.

    Engine knock or rattle sound when climbing a long grade and towing a heavy

    trailer.

    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

    thermostat repairs.

    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.

    014-All

    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

    climates/temperatures elsewhere.

    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

    procedure.

    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.

    009-All

    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

    and gear.

    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

    requiring MS5931.

    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

    requiring MS5931.

    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.

Benefits:

    ? 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

    04/08/06.

    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

    panel.

    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

    06

    ? 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

    blades/elements.

    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

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