Back Issue Index
 
  MAGAZINE
Purpose  
Digital Magazines  
Sample Articles  
Magazine Index  
Ready To Travel  
Buyer's Guide  
Kevin Cameron's Collection  
Technical FAQ  
Dodge/Cummins History  
Classified Ads 
Subscribe/Renew  
Request Free Issue  
Gift Subscription  
Buy Back Issues  
Buy TDR Logo Items  
Advertising  
TDR Advertisers  
Membership Drive  
 

 TSB's for 2005 trucks

Category 2 - Front Suspension

Category 3 - Rear Axle

03-003-06 All Axle-fluid level.
This bulletin supersedes TSB 03-001-04, revision A dated 5/11/04.
The axle fi ll holes on some 2004 Dodge Truck axles may be located considerably higher than the actual fl uid level. Filling the axle until the fl uid comes out of the fi ll hole will overfi ll the axle, which could cause fl uid foaming. When checking fl uid level or fi lling a rear axle with fl uid, you must measure distance from the bottom of the fi ll hole to the actual fl uid level. This can easily be accomplished using a pipe cleaner or piece of wire. Make a 90 degree bend in the wire two inches from the end. The wire can then be inserted into the axle fi ll hole and used as a dipstick. Measure the distance from the bend to the oil level. The fl uid levels for the axles are shown in the table below.

Ram Truck 2500/3500
AxleFluid Level (measured from the bottom of the fill hole)Fluid Capacity
10.5 Rear Axle1 inch ± ¼ inch85 oz. SAE 75W-90 Synthetic
11.5 Rear Axle¼ inch ± ¼ inch122 oz. SAE 75W-90 Synthetic
9 ¼ Front Axle¼ inch ± ¼ inch76 oz. SAE 75W-90 Synthetic
Note: The limited slip feature on 2500/3500 series Ram Trucks utilizes the Trac Rite locking feature which does not require Trac-Lok additives or friction modifi ers.

Category 5 - Brakes

Category 6 - Clutch

Category 7 - Cooling

Category 8 - Electrical

08-014-05 All Mopar accessory remote starter inoperative due to hood switch.
This bulletin applies to vehicles equipped with a Mopar remote starter kit. The problem frequently occurs as one or more of the following:
  • When the transmitter is pressed twice for start, the vehicle horn will chirp once but the vehicle engine will not start.
  • When the transmitter is pressed twice for start, the vehicle horn will chirp twice, indicating a problem with the remote start system and the vehicle engine will not start.
  • When the transmitter is pressed twice for start the vehicle will chirp once, the engine will start an then turn off.
The technician may not be able to verify the symptom(s) because it may be an intermittent condition. The corrective action involves replacing the hood switch for the remote starting system.
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.
08-058-05 All Revised Radio antenna mast installation procedure.
This information only bulletin advises the proper tightening torque (30-32 in-lbs) for the radio antenna mast for various Chrysler group products.
08-046-06 All Cell phone induced buzz or clicking-like sound in radio speakers.
This bulletin involves a discussion regarding cell phone generated signal interference with the vehicle radio system. A customer may experience a buzzing or clicking-like sound coming from the vehicle radio speaker(s). The sound may be heard when the radio is in AM or FM mode. The clicking-like sound may sound like Morse code.

This information-only bulletin points out that the construction of certain cell phones may generate frequencies that can interfere with the vehicle radio system. These frequencies may result in buzzing and/or clicking-like sounds in the vehicle radio. This condition can be easily corrected by instructing the customer to move their cell phone away from the immediate area around vehicle radio system (radio, radio amplifier, antenna, antenna lead). Do not replace any radio system component in an attempt to address this condition.

Category 9 - Engine

09-004-06 All Accessory drive belt chirp at shut down.
A chirping sound may be heard coming from the accessory drive belt when the engine is shut down. If a customer indicates that the condition is present, the bulletin directs the technician to install an overrunning clutch pulley on the generator.

Category 11 - Exhaust

Category 13 - Frame/Bumper

Category 14 - Fuel

14-004-05 All Electronic fuel control (EFC) actuator available for service
This bulletin deals specifically with an engine surge at idle condition. The diagnostic procedures are the same as those listed in TSB 14-003-05. The bulletin describes the repair procedure for replacement of the electronic fuel control actuator.
14-003-06
Rev. A		 All Cummins diesel diagnostics.
This bulletin applies to vehicles with the 5.9 liter engine, sales code ETH or ETC.
Revised diagnostic procedures are available for the following conditions:
  • Engine cranks for a long time or will not start
  • White smoke and/or misfire after starting when the engine temperature is below 150° F
  • Engine surges at idle
  • Engine sounds
The 12-page bulletin gives the service technician a set of revised diagnostic procedures for the fuel system. Each condition is discussed and possible causes are established. Step-by-step instructions help the technician identify and repair the problem.

Category 16 - Propeller Shafts & U-joints

Category 18 - Vehicle Performance

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.
18-003-06
Rev. A		 All Flash: long crank when starting and/or transmission shift and battery charging enhancements.
This bulletin applies to Ram trucks equipped with the 5.9L Cummins 24-valve diesel engine (sales code ETH) built on or after January 1, 2005. The vehicle operator may experience extended engine crank time in cold ambient temperatures on vehicle equipped with manual transmissions. This flash also provides the following enhancements:
  • Improved start times for manual transmission vehicles
  • Improved automatic Transmission shifting
  • Engine fan is activated if the coolant temperature sensor fails
  • Enhanced battery charging
This bulletin involves flash reprogramming the PCM (Cummins) with the software.
18-022-07 All Flash: 5.9L Turbo-Diesel engine system enhancements
This bulletin applies to vehicles equipped with a 5.9L Turbo Diesel engine (sales codes ETC and ETH respectively). The bulletin supersedes 18-022-06 dated 07/13/06. The following enhancements are included with this software update:
  • Improved engine cooling (radiator fan activation) and prevention of possible engine overheat. When coolant temperature faults are present the radiator fan is enabled (turned on) during vehicle operation.
  • Correction to oil pressure reading when engine is operating at higher engine temperatures above 195°F.
  • Improvement to the Temperature Sensor Rationality Test to prevent possible false test failures and their following related diagnostic trouble codes:
    DTC P0071 – Inlet Air Temperature Sensor Rationality
    DTC P0111 – Intake Air Temperature (IAT) Sensor Rationality
    DTC P0514 – Battery Temperature Sensor Rationality.
  • Additional water-in-fuel (WIF) warning added to indicate that the operator has had a WIF (DTC P2269) and has continued to operate the vehicle in excess of 500 miles without draining the water from the fuel fi lter. The following is the new WIF DTC that has been added: DTC P0169 – WIF Too Long Error
  • Improvement to the fuel pressure rationality test to prevent false test failures and the related DTC 0191.
This bulletin involves selectively erasing and reprogramming the engine control module with new software.
18-030-07 DR/DH/D1/DC Engine off-idle speed limit feature to protect turbocharger when vehicle is not moving.
This bulletin applies to vehicles equipped with a 5.9-liter or a 6.7-liter Cummins Turbo Diesel engine (sales codes: ETC, ETH, or ETJ). This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving.

Dependent upon engine coolant temperature, the engine control module (ECM) will temporarily limit the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger.

This delay in maximum engine and turbocharger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings which is important for long term turbocharger durability.

The maximum engine speed for the 5.9-liter engine is temporarily limited to 1,600 RPM when the above conditions are met. The 6.7-liter engine speed is temporarily limited to 1,200 RPM when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. For example, the delay can be up to 45 seconds at 35° or 7 seconds at 70°.

Category 19 - Steering

19-010-04 All Power steering fluid contamination.
This information only bulletin discusses the use of supplements to the power steering fluid. Do not use fluids or supplements that contain Teflon as they will cause a restriction at the filter in the power steering system. The power steering fluid used in Chrysler Group vehicles is an engineered product. The addition of any unapproved fluids or supplements can interfere with the proper function of the fluid and cause damage to the steering systems, use only Mopar Power Steering Fluid +4, ATF+4 automatic transmission fluid, or equivalent (MS-9602), in the power steering system.
19-003-05 All In and out movement in steering column.
This bulletin applies to vehicles built after December 1, 2003. Should there be a small amount of movement in the steering column when pulling the steering wheel toward you while seated in the driver's seat, the TSB outlines the proper repair procedure which involves the installation of a steering retainer kit to the steering column.
19-008-05
Rev. A		 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 fluid +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 fluid is to be used in these systems. Damage may result to the power steering pump and system if the incorrect fluid 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

21-006-06 All Transmission jumps out of reverse.
This bulletin applies to vehicles equipped with Cummins Turbo Diesel engines, sales code ETH and G56 manual transmissions sales code DEG. A customer may experience the transmission jumping out of reverse. If the customer indicates that the condition is present, perform the repair procedure which involves replacing the reverse synchronizer.
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.
21-006-07 DH Flash: New 48RE feature that allows normal shift schedule with full disable of 4th gear overdrive.
This bulletin applies to vehicles equipped with a 5.9-liter Cummins Turbo Diesel engine and a 48RE automatic transmission (sales codes ETH and DG8 respectively). A new 48RE transmission feature is added 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).

This bulletin involves selectively erasing and reprogramming the Cummins Engine Control Module (ECM) with new software.
21-009-07 All 48RE Transmission – 1-2 shift hunt at light throttle.
The customer may experience a 1-2 shift transmission hunt during light throttle application. This condition may be due to a governor pressure solenoid valve. This bulletin involves the replacement of the governor pressure solenoid valve in the transmission valve body.
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.
22-005-06 DR/DH/D1/DC Front end shimmy on 4x4 vehicles when traveling over rough surfaces in the road.
This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure.

If the customer experiences the above condition, perform the repair procedure which includes a steering damper, tie rods and end links.

Category 23 - Body

23-015-05 All Transit film removal.
This information only bulletin provides a transit film removal procedure.
23-022-05 All Low gloss interior trim.
This information only bulletin discusses that all Chrysler, Dodge, and Jeep vehicles are designed with a low gloss interior trim. This low gloss finish maintains pleasing aesthetis, and minimizes glare of the instrument panel into the windshield. This low gloss finish should not be altered with a medium or high gloss interior treatment solution such as MOPAR Protector's or other Armor All-like products.

Instead, MOPAR Satin Select (part number 05174395AA) which has been specifically developed to remove minor surface contamination and maintain the low gloss appearance should be used for interior trim treatment.
23-049-05 All Drip rail door seal torn.
The drip rail or secondary door seal may become torn from contact with the lower “A” pillar of the front door. The repair involves replacing the secondary door seal with an improved seal.
23-009-06 All Water leak at roof mounted marker lamps.
Water leaks may be present coming from the roof mounted marker lamps. New marker lamps have been released which contain base gaskets. These marker lamps should be used in all cases where water leaks are present at the marker lamps. These lamps will have to be replaced in sets of five due to appearance differences. If water leak tests reveal that water leaks are present at the marker lamps, perform the repair procedure.
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.
23-004-07 All Transit film removal.
This information only bulletin provides a transit film removal procedure
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

24-006-06 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

Recalls

SAFETY RECALL E17
OUT-OF-PARK ALARM SYSTEM
'03-'04 DR
'05 DH
This recall applies only to the above vehicles equipped with a 5.9L diesel engine (6 or C in the eighth VIN Position) and an automatic transmission (sales code DGP or DG8). In certain cirumstances when a driver has not placed the shifter lever fully into the "Park" position and leaves the engine running, the vehicle may unexpectedly move rearward after seeming to be stable. Unintended rearward movement of a vehicle could injure those in and/or near the vehicle.

Repair: An Out-of-Park alarm system must be installed on the vehicle. The alarm system will beep the horn and flash the headlamps and shift indicator if a driver tries to exit a running vehicle without fully placing the shifter into the "Park" position.
CUSTOMER SATISFACTION NOTIFICATION E10
FRONT SUSPENSION COIL SPRINGS
Date: July 2005
Models: '05 (DH) Dodge Ram 3500 4x2 Pickup Truck

This notification applies only to the above vehicles built through May 27, 2005. Incorrect front coil springs may have been installed on about 8,100 of the above truck’s front suspension. This may cause the front suspension to bottom out prematurely, which can reduce ride quality.

Repair: Both front suspension coil springs must be replaced.

TDR Magazine and Website's Purpose

Copyright © 1999-2008 Turbo Diesel Register, All Rights Reserved. Click Here for our privacy policy and legal notices. 1