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TSB's for 2009 trucks

Category 2 - Front Suspension

Category 3 - Rear Axle

Category 5 - Brakes

Category 6 - Clutch

Category 7 - Cooling

Category 8 - Electrical

08-035-08

2500/3500

Proper testing tools for oxygen sensor terminals.
This bulletin describes the use of proper test probes to test the oxygen (O2) sensor connector terminals equipped with the new TP2 style sensor. The recommended tool for these testing procedures is the Miller Tool #6801.

Category 9 - Engine

09-002-09
Rev A.

2500/3500

MIL illumination due to DTC P2262 - Revised diagnosis and repair procedures.
This bulletin applies to vehicle equipped with a Cummins 6.7-liter engine (sales code ETJ). The bulletin supersedes technical service bulletin 09-002-09 dated 5/2/09. This bulletin discusses revised diagnostic and repair procedures for DTC P2262 - Turbocharger Boost Pressure Not Detected - Mechanical. Recent PCM calibration updates have improved the robustness to this DTC through updated diagnostic strategies. As a result, many events which have no adverse affects on drivability, emissions, or reliability will no longer set the P2262 fault.

As a result of recent PCM calibration updates, the proper repair for some P2262 faults is merely to update the calibration, while others will require cleaning or replacing the turbocharger. Scan Tool software includes a P2262 diagnosis test for this purpose. The new P2262 diagnosis test must be used prior to performing any of the following:

Clearing codes
Updating the PCM
Beginning the turbocharger repair.

Based on the outcome of the P2262 diagnosis test, the Scan Tool will provide one of the following as the proper direction for the appropriate repair. Service info and complete the repair as directed:

Update PCM flash calibration to the latest calibration. No repair required to the turbocharger.
Clean the turbocharger.
Update PCM flash calibration to the latest calibration and clean the turbocharger.
Replace the turbocharger.
Update PCM flash calibration to the latest calibration and replace the turbocharger.

Category 11 - Exhaust

11-001-09	2500/3500	Diesel Particulate Filter: Diagnosis and repair of DTC’s P1451, P200C, P242F or black smoke from exhaust. This bulletin applies to vehicles equipped with a Cummins 6.7-liter engine (sales code ETJ). The customer may experience a malfunction indicator lamp (MIL) illumination, warning chime and an overhead electronic vehicle information center (EVIC) message regarding the aftertreatment system and/or black smoke from the exhaust and/or a no start condition. Further investigation by the technician may reveal that the MIL illumination and/or EVIC message is due to one or more of the following diagnostic trouble codes (DTC’’s): P1451 - Diesel Particulate Filter - System Performance P242F - Diesel Particulate Filter Restriction - Ash Accumulation P200C - Diesel Particulate Filter Over Temperature - Bank 1. This bulletin provides revised diagnostic and repair procedures for DTC’s P1451, P200C, P242F, black smoke from the exhaust, or a no start condition due to a nonfunctional or plugged diesel particulate filter (DPF).
11-002-09	2500/3500	Diesel particulate filter Stationary DeSoot. This bulletin applies to D1/DH vehicles equipped with a 6.7-liter Cummins diesel engine (sales code ETJ). Mobile DeSoot still applies to DC/DM vehicles equipped with the 6.7-liter Cummins diesel engine (sales code ETJ). Stationary DeSoot has replaced Mobile DeSoot as the repair for Diagnostic Trouble Codes P1451 and P2463. This bulletin provides the procedure to perform Stationary DeSoot. This new procedure allows running the DeSoot in a secured area with the vehicle unattended. Stationary DeSoot can only be performed when the diesel particulate filter has exceeded a specified soot threshold. The Diagnostic Scan Tool will not allow the procedure to operate unless the threshold has been exceeded. If the vehicle does not have an active P1451, the soot in the Diesel Particulate Filter is at a normal level and a scan tool initiated DeSoot is not needed.

Category 13 - Frame/Bumper

Category 14 - Fuel

Category 16 - Propeller Shafts & U-joints

Category 18 - Vehicle Performance

18-013-08
Rev. A

2500/3500

Engine system and exhaust aftertreatment system enhancements.
This bulletin applies to vehicles equipped with a Cummins 6.7-liter engine (sale code ETJ) built on or before November 27, 2008. This bulletin supersedes technical service bulletin 18-013-08, dated March 13, 2008. This bulletin involves verifying that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first, then verify the software level, and if necessary, selectively erasing and reprogramming the Engine Control Module (ECM) with new software. Additionally, verify the software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. With this latest ECM software release listed in this Service Bulletin, the following symptoms have been completely addressed.
One of the following drivability conditions

One of the following driveability conditions:
a. An intermittent rough engine idle and/or white smoke following initial engine start.
b. A throttle tip-in stumble at engine speeds of 1,300 to 2,100 rpm.
c. An engine hesitation at altitude of 5,000 feet between engine speeds of 1,200 to 1,600 rpm.
d. A turbocharger “chuff-like” sound during rapid deceleration.
The vehicle may fail an Emission Inspection Maintenance (I/M) Test because two or more On- Board Diagnostic (OBD) monitors report that they are not ready for testing. This condition may cause the customer vehicle to not pass an Emissions I/M test. The following is a list of OBD Monitors that may report as not ready for testing:
a. Non-Methane Hydrocarbon (NMHC) Catalyst Monitor.
b. Nitrogen Oxide (NOx) Absorber Monitor.
c. Exhaust Gas Temperature Sensor Monitor.
d. Electrical Charging System Monitor.
e. EGR System Monitor.
f. Oxygen Sensor Monitor.
Malfunction Indicator Lamp (MIL) due to one or more of the following Diagnostic Trouble Codes (DTC’s):
a. P0101 - Mass Air Flow (MAF) Sensor Rationality
b. P0128 - Thermostat Rationality
c. U1421 - Implausible Ignition Key Off Time Received.

The latest ECM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time.

A number of improvements have been made to the engine diagnostics. Performing this Service Bulletin completely will enable these diagnostic improvements.

To determine if the vehicle has the latest software, compare the software level to the following notes:

If the vehicle in question is a 2007 model year vehicle, then compare the current ECM software level part number to one of the following part numbers (or with a higher suffix):
55350430AZ (or higher) = DH 2500 6.7L Manual Transmission 50 State
55350435AZ (or higher) = DH 2500 6.7L Automatic Transmission 50 State
55351430AZ (or higher) = D1 3500 6.7L Manual Transmission 50 State
55351435AZ (or higher) = D1 3500 6.7L Automatic Transmission 50 State
If the vehicle in question is a 2008 model year vehicle, then compare the current ECM software level part number to one of the following part numbers (or with a higher suffix):
62350430AR (or higher) = DH 2500 6.7L Manual Transmission 50 State
62350435AR (or higher) = DH 2500 6.7L Automatic Transmission 50 State
62351430AR (or higher) = D1 3500 6.7L Manual Transmission 50 State
62351435AR (or higher) = D1 3500 6.7L Automatic Transmission 50 State
If the vehicle in question is a 2009 model year vehicle, then compare the current ECM software level part number to one of the following part numbers (or with a higher suffix):
72350430AF (or higher) = DH 2500 6.7L Manual Transmission 50 State
72350435AF (or higher) = DH 2500 6.7L Automatic Transmission 50 State
72351430AF (or higher) = D1 3500 6.7L Manual Transmission 50 State
72351435AF (or higher) = D1 3500 6.7L Automatic Transmission 50 State
Determine if the current CCN module level software part number is one of the following (or with a higher suffix):
05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500)
05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500)
05172529AG (or higher) = 2009 DH (2500) or 2009 D1 (3500)

18-001-09

3500/4500/5500 Cab Chassis

Engine systems and exhaust aftertreatment systems enhancements.
This bulletin applies to vehicles equipped with a Cummins 6.7-liter engine (sales code ETJ) built on or before January 13, 2009. This bulletin supersedes technical service bulletin 18-009-07 Rev. B, dated July 13, 2007.
This bulletin involves verifying that the latest software has been installed on 2007 MY vehicles. Selectively erasing and reprogramming the Engine Control Module (ECM). Selectively erasing and reprogramming the Cab Compartment Node (CCN).

The latest PCM software will address the erroneous MIL illumination of the following faults:

P0191 - Fuel Rail Pressure Sensor Circuit Performance
P0128 - Thermostat Rationality
P0106 - Manifold Absolute Pressure Sensor Performance
P0524 - Engine Oil Pressure Too Low
P061A - ETC Level 2 Torque performance
P0607 - ECU Internal Performance

The latest PCM software will include the following operational and diagnostic improvements: Improve engine cooling capability and prevention of over temp condition (P0217 - Coolant Temperature Too High) when operating with snow plow. New feature that allows for customer selectable remote PTO speed (if equipped). The latest ECM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time.

To determine if the vehicle has the latest software, compare the following notes:

If the vehicle in question is a 2007 model year vehicle, then compare the current PCM software level part number to one of the following part numbers (or with a higher suffix):
52300430AX (or higher) = DC 3500 6.7L Manual Transmission 50 State
55300434AX (or higher) = DC 3500 6.7L Automatic Transmission 50 State
If the vehicle in question is a 2008 model year vehicle, then compare the current PCM software level part number to one of the following part numbers (or with a higher suffix):
61300430AK (or higher) = DC 3500 6.7L Manual Transmission 50 State
61300434AK (or higher) = DC 3500 6.7L Automatic Transmission 50 State
61301430AK (or higher) = DM 4500/5500 6.7L Manual Transmission 50 State
61301434AK (or higher) = DM 4500/5500 6.7L Automatic Transmission 50 State
If the vehicle in question is a 2009 model year vehicle, then compare the current PCM software level part number to one of the following part numbers (or with a higher suffix):
71300430AH (or higher) = DC 3500 6.7L Manual Transmission 50 State
71300434AH (or higher) = DC 3500 6.7L Automatic Transmission 50 State
71301430AH (or higher) = DM 4500/5500 6.7L Manual Transmission 50 State
71301434AH (or higher) = DM 4500/5500 6.7L Automatic Transmission 50 State
Determine if the current CCN module level software part number is one of the following (or with a higher suffix):
05172187AH (or higher) = 2007 DC (3500) / DM (3500/4500)
05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500)
05172529AG (or higher) = 2009 DC (3500) / DM (3500/4500)

18-024-09

DH/D1

MIL illumination and stationary DeSoot and other enhancements.
This bulletin applies to D1/DH vehicles equipped with a 6.7-liter Cummins engine (sales code ETJ) built before May 5, 2009. The customer may experience:

An erroneous MIL illumination for P2262 - Turbocharger Boost Pressure Not Detected - Mechanical.
Improved diagnostics for P2299 - Brake Pedal Position/Accelerator Pedal position Incompatible.
An erroneous MIL illumination for P0402 - Exhaust Gas Recirculation (EGR) Flow Excessive Detected.
An erroneous MIL illumination for P040B - EFR Temperature Sensor 1 Circuit Performance.
An erroneous MIL illumination for P0405 - EFR Position Sensor Circuit Low.

This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software.

Category 19 - Steering

Category 21 - Transmission

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

Category 23 - Body

Category 24 - Air Conditioning

Category 25 - Emissions

Category 26 - Miscellaneous

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