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TSB's for 2002 trucks

Category 2 - Front Suspension

02-003-02

All

Toe-in specification change.
This bulletin involves an update to the toe-in specification for front end alignments. The specification for toe-in has been revised to 0.2° +- 0.1° total 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

03-001-02	All	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 after January 4, 2002 and equipped with front axles with the following part 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 procedures.
03-002-02	All	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 trailer towing conditions that when service is being performed on the 9 1/4" rear axle on 2002-2003 (DR) Ram trucks, the axle must be refilled with Mopar 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

08-010-01	All	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 on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Any repair that may disrupt the 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.
08-016-02	All	Horn chirp and erroneous alarm. This bulletin involves reprogramming the forward control module (FCM) should there be an erroneous horn chirp when a door is opened or an erroneous alarm. The correction is a reflash of the FCM.
08-004-03	All	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 diesel engine equipped vehicles. 2. An intermittent false chime and �Low Wash� indicator. 3. A �Trans Temp� indicator on a manual transmissions equipped vehicle. This bulletin involves selectively erasing and reprogramming the MIC with new software.
08-024-05	All	Radio communication equipment installation recommendations. This information only bulletin gives the dealership technician some guidelines for the installation of two-way radio equipment.

Category 9 - Engine

09-003-01	All	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 intervals. No additive is known to be safe for engine durability and can degrade emission components. Additives can contain undesirable materials 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.
09-006-01	All	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 applied without the use of Mopar Silicon Rubber Adhesive (RTV) Sealant (PN 04883971). This bulletin provides routing of the sealant when replacing the 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.
09-002-02	All	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 the front crankcase breather when the vehicle is operated off-road on an extreme downhill grade (37.5% or 22° slope/grade). Operation of this type for 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.
09-008-02	All	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 Cummins diesel engine (sales code ETC or ETH). Owners may experience an engine knock or rattle sound when climbing a long grade while towing a heavy 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

14-001-02 A

All

Fuel cap difficult to remove.
This bulletin involves installing a revised fuel cap.

14-002-02 A

All

Tampering with VP44 fuel pump on Cummins diesel engine.
This bulletin supersedes technical service bulletin 14-002-02, dated July 1, 2002. A number of the VP44 fuel pumps have been returned through the 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:

DTC	P Code	Description
124	P 0234	Turbo boost limit exceeded.
146	P 0217	Decreased engine performance due to engine overheat condition.
361	P 0254	Fuel injection pump fuel valve current too high.
363	P 0251	Fuel injection pump mechanical failure fuel valve feedback 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

18-014-01	All	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 and/or idle speed fluctuations condtion. 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.
18-019-01	All 24v engines	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) * The transmission is in Neutral or Park * The Service Brake pedal is not depressed * 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)
18-030-03	All	Generic Cummins engine control module (ECM) procedure. This bulletin applies to Ram trucks equipped with the 5.9L Cummins 24-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.
18-030-03	All	Generic Cummins engine control module (ECM) procedure. This bulletin applies to Ram trucks equipped with the 5.9L Cummins 24-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.
18-033-04	All	Cummins engine control module (ECM) procedure. 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 at the dealership. This bulletin describes the programming procedure.

Category 19 - Steering

19-009-01	All	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 serviceable horn switch issues, are subject to charge back. 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.
19-003-02	All	Hissing sound coming from the power steering system on vehicles equipped with hydroboost brakes. A hissing sound may be present in the power steering system during steering maneuvers or straight ahead driving. This bulletin involves replacing the power steering hoses connecting the hydroboost to the power steering pump and gear.
19-005-03	All	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 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.
19-005-03	All	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 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.
19-008-05	All	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-9602) is to be used in the power steering system of DR vehicles. No other power steering or automatic transmission fl uid is to be used in these systems. 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

21-006-01	Auto trans	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. ATF+4 must always be used in vehicles that were originally filled with ATF+4. 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.
21-009-03	All	Automatic transmission diagnostic teardown procedure. This bulletin provides a procedure to determine repair versus replacement of an automatic transmission assembly.
21-010-06	Auto	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: Better anti-wear properties Improved rust/corrosion prevention 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.
21-003-07	All	Automatic transmission diagnostic tear down procedure. This bulletin provides a procedure to determine repair versus replacement of an automatic transmission assembly. Follow the proper repair procedure based on the transmission type. This procedure is to be used after the transmission has been removed from the vehicle. This bulletin supersedes technical service bulletin 21-008-06, dated 04/08/06.
21-014-07	All	Automatic transmission fl uid usage ATF+4 (Type MS9602). This bulletin supersedes technical service bulletin 21-010-06, dated 4/16/06. 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: Sprinter transmissions, Crossfi re transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) all vehicles equipped with a A568RC transmission (sales code DG3), all vehicles with a Gentrag MP56 (sales code DG5), and Grand Cherokee�s with the diesel engine option. 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+. Benefits: Better anti-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 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.
21-021-08	All	Automatic transmission diagnostic tear down procedure. This bulletin provides a procedure to determine repair versus replacement of an automatic transmission assembly. Follow the proper repair procedure based on the transmission type. This procedure is to be used after the transmission has been removed from the vehicle.

Category 22 - Wheels & Tires

22-001-05

All

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 stain wheels and wheel trim.

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

23-027-01	Equipped with 6x9 Mirrors Sales Code GPS or GPU	Outside rearview mirror glass replacement. This bulletin supercedes technical service bulletin 23-034-00 Rev. A dated December 15, 2000. It is unnecessary to replace the entire outside rearview mirror assembly when the mirror glass is broken or is missing. Replacement mirror glasses are available from Mopar. Because of the extremely long list of part numbers involved, please consult the Mopar parts catalog for the correct part number(s).
23-003-04	All	Water leak at grab handle. Water may enter the vehicle through the secondary door seal retainer or the roof seam, onto the headliner and run down the �A� pillar, coming out at the grab handle. The repair involves sealing holes in the roof panel.
23-014-06	All	Windshield wiper blade maintenance. Windshield wiper blades/elements are frequently replaced unnecessarily. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 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.
23-013-07	DR/DH/D1/DC	Trailer Towing Mirror � New mirror glass locking tab, new removal procedure. This bulletin applies to vehicles equipped with trailer tow mirrors (sales codes GPD or GPG) built after April 16, 2007, and for any vehicle where service replacement of the mirror glass is required. The trailer towing mirror assembly has a replaceable mirror glass. As part of the replaceable mirror glass, a locking tab has been added to the plastic backing on the mirror glass. This change has been made to vehicles built after April 16, 2007. This change is also being incorporated in service replacement mirror glass. This bulletin involves a discussion regarding new removal procedure when replacing the mirror glass on a trailer tow mirror.

Category 24 - Air Conditioning

24-009-02	All Chrysler group products using R-134A refrigerent	A/C system leak detection. Vehicles from the factory no longer have leak detection dye in the A/C system. To determine the source of a R-134a leak, a leak tracer dye has to be injected into the A/C system.
24-003-03	All Chrysler group products	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 regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks 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.
24-006-06	All	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, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C 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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