3rd Gen Technical Service Bulletins

Tsb 19: Camshaft sprocket retaining bolts

Service bulletin #: 19
replacement sb#:
Nhtsa item #: 10006902
date: 20040401
failing component: 061000 engine and engine cooling:engine
make: Dodge
model: Ram
year: 2004
date created: 20040519
description of summary: The camshaft sprocket retaining bolts may not have been properly tightened. A loose cam sprocket bolt can back out and cause significant engine damage. Customer satisfaction notification no. D19. *tt

tsb 1802104: DTC P0401, P0403, P0404, P0405, P0406.

SERVICE BULLETIN #: 1802104
REPLACEMENT SB#:
NHTSA ITEM #: 10007936
DATE: 20040504
FAILING COMPONENT: 110000 ELECTRICAL SYSTEM
MAKE: DODGE
MODEL: RAM
YEAR: 2004
DATE CREATED: 20040716
DESCRIPTION OF SUMMARY: MALFUNCTION INDICATOR LAMP (MIL) ILLLUMINATION DIAGNOSTIC TROUBLE CODES P0401, P0403, P0404, P0405, P0406. *MJ

NOTE: This bulletin applies to vehicles equipped with a 5.7L engine (sales code EZA) built on or before March 12, 2004 (MDH 0312XX).

NOTE: Service Bulletin 18-010-04 must be performed in conjunction with this repair.

CAUTION: Do not start the engine between installing the EGR Valve and performing TSB 18-010-04 (PCM Flash Reprogramming). Both repairs must be performed before the engine is started.
1. Open the hood.
2. Disconnect the battery.
3. The electronic EGR valve and solenoid assembly is attached to the front of the right cylinder head. An exhaust gas routing tube connects the EGR valve to the intake manifold.
4. Disconnect the electrical connector from the EGR solenoid.
5. Remove the two bolts connecting the EGR tube to the EGR valve assembly.
6. Remove the gasket located between the EGR tube flange and the EGR valve assembly.
7. Remove two EGR valve to cylinder head mounting bolts.
8. Separate the EGR valve assembly from the cylinder head.
9. Remove and discard the metal gasket located between the cylinder head and the EGR valve assembly.
10. Clean both gasket surfaces on the EGR tube and the cylinder head.
11. Position a new metal gasket (p/n 53032212AA) between the cylinder head and the new EGR valve assembly (p/n 53032209AE).
12. Install the two EGR valve to cylinder head mounting bolts and tighten to 29.9 Nm (265 in. lbs.).
13. Position a new gasket, p/n 05277928, between the EGR tube flange and the EGR valve assembly.
14. Install the two bolts connecting the EGR tube to the EGR valve assembly (Figure 1). Tighten the bolts to 11.8 Nm (105 in. lbs.).
15. Connect the electrical connector to the EGR solenoid.
16. Connect the battery negative cable.
17. Perform Service Bulletin 18-010-04 in conjunction with this repair.
CAUTION: Do not start the engine between installing the EGR Valve and performing SB 18-010-04 (PCM Flash Reprogramming). Both repairs must be performed before the engine is started.

Tsb 0300304: Differential unit

SERVICE BULLETIN #: 0300304
REPLACEMENT SB#:
NHTSA ITEM #: 10008043
DATE: 20040615
FAILING COMPONENT: 105500 POWER TRAIN : DRIVELINE : DIFFERENTIAL UNIT
MAKE: DODGE
MODEL: RAM
YEAR: 2003, 2004
DATE CREATED: 20040720
DESCRIPTION OF SUMMARY: LAUNCH SHUDDER. *TT

NOTE: This bulletin applies to vehicles equipped with a two piece rear driveshaft.

Repair Procedure:
1. Inspect the suspension and drive line for any signs of worn or damaged parts. Make the necessary repairs.
2. Raise the vehicle on a hoist. The weight of the vehicle must be supported by the
suspension. Make sure that the frame is as level as possible.
3. Remove universal joint snap rings if equipped, so Inclinometer No. 7663 base sits flat.
4. Rotate shaft until transmission/transfer case output yoke bearing is facing downward.
NOTE: Always take measurements from front to rear and on the same side of the vehicle.
5. Place inclinometer on yoke bearing cap or pinion flange ring parallel to the shaft. Center the bubble in sight glass and record measurement. This measurement will give you the transmission yoke Output Angle .
6. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft . Center the bubble in sight glass and record measurement. This measurement can
also be taken at the rear end of the shaft. This measurement will give you the Front Propeller Shaft Angle .
7. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to therear shaft and center the bubble in the sight glass and record measurement. This
measurement can also be taken at the rear end of the shaft. This measurement will give you the Rear Propeller Shaft Angle .
8. Rotate propeller shaft 90 degrees and place inclinometer on rear axle pinion flange yoke
bearing parallel to the shaft. Center the bubble in sight glass and record measurement.
This measurement will give you the Pinion Flange Input Angle or Pinion Angle.
9. To calculate the operating angle for the transmission output to front propeller shaft, subtract front propeller shaft angle from the transmission output shaft. To
calculate the operating angle for the front to rear propeller shaft, subtract
the front prop. rear propeller shaft angel from the front. To calculate the operating angle
for the rear prop. shaft to pinion angle, subtract the pinion angle from the
rear prop. shaft angle. The operating angles can be adjusted by moving the center
carrier bearing up or down. The center bearing brackets, listed above, are available in a
variety of heights. The working angles should be adjusted to provide the lowest angle
possible for the output shaft to front propeller shaft, front propeller shaft to rear propeller
shaft and rear propeller shaft to axle pinion. The angles must be below 3 degrees but
must have a minimum angle of 1/2 degree to provide for universal joint lubrication.
Determine which direction you need to move the center bearing to optimize the angles
and install the appropriate bracket to obtain the minimum working angle, but still
maintain at least 1/2 degree to assure that there will be some movement in the U-joint
bearings.

TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs.
Center Bearing Bolts 54 40
Transfer Case Flange Bolts 88 65
LD - Front Pinion Flange Bolts 115 85
HD - Front Pinion Flange Bolts 28 21
Rear Pinion Flange Bolts 115 85
Rear Pinion Yoke Bolts 29 22

Tsb 0300404: Differential unit

SERVICE BULLETIN #: 0300404
REPLACEMENT SB#:
NHTSA ITEM #: 10008044
DATE: 20040622
FAILING COMPONENT: 105500 POWER TRAIN : DRIVELINE : DIFFERENTIAL UNIT
MAKE: DODGE
MODEL: Ram Truck (Diesel)
YEAR: 2003, 2004
DATE CREATED: 20040720
DESCRIPTION OF SUMMARY: AXLE WHINE. *TT

NOTE: This bulletin applies to 4X2, 2500 series, 140.5 inch wheel base vehicles
equipped with diesel engine, sales code ETC/ETH, and automatic transmission,
sales code DG8.

Parts Required:
Qty. Part No. Description Application
1 52853051AA Propeller Shaft 2500 5.9L TD Std Output, 4x2, 140.5 Wheel Base, 48RE, 10.5 in. Axle , Standard Pinion Flange
1 52853051AB Propeller Shaft 2500 5.9L TD Std Output, 4x2, 140.5 Wheel Base, 48RE, 10.5 in. Axle, Light Weight Pinion Flange
1 52853053AA Propeller Shaft 2500 5.9L TD High Output, 4x2, 140.5 Wheel Base, 48RE, 10.5 in. Axle , Standard Pinion Flange
1 52853053AB Propeller Shaft 2500 5.9L TD High Output, 4x2, 140.5 Wheel Base, 48RE, 10.5 in. Axle, Light Weight Pinion Flange
1 52105643AD Propeller Shaft 2500 5.9L TD Std Output, 4x2, 140.5 Wheel Base, 47RE, 10.5 in. Axle , Standard Pinion Flange
1 52105643AE Propeller Shaft 2500 5.9L TD Std Output, 4x2, 140.5 Wheel Base, 47RE, 10.5 in. Axle, Light Weight Pinion Flange
1 52105645AD Propeller Shaft 2500 5.9L TD High Output, 4x2, 140.5 Wheel Base, 47RE, 10.5 in. Axle , Standard Pinion Flange
1 52105645AE Propeller Shaft 2500 5.9L TD High Output, 4x2, 140.5 Wheel Base, 47RE, 10.5 in. Axle, Light Weight Pinion Flange

Repair Procedure:
1. Raise the vehicle on a hoist and inspect the rear axle pinion flange(Figure 1). There a re
two types of pinion flanges used. Standard and light weight. Identify the flange and
choose the appropriate propeller shaft from the chart above. The type of flange is
important as the flanges are different in length and require a matching propeller shaft.

2. Install the appropriate drive shaft listed in the chart above. Tighten the flange bolts to
115 Nm (85 ft. lbs.).

Tsb 2302904: Power window devices and controls

SERVICE BULLETIN #: 2302904
REPLACEMENT SB#:
NHTSA ITEM #: 10009797
DATE: 20040802
FAILING COMPONENT: 133000 VISIBILITYOWER WINDOW DEVICES AND CONTROLS
MAKE: DODGE
MODEL: RAM
YEAR: 2004
DATE CREATED: 20041025
DESCRIPTION OF SUMMARY: FRONT POWER WINDOW BINDS. *TT

Parts Required:
Qty. Part No. Description
1 06100876 Washer


Repair Procedure:
1. Separate the door trim panel from the door, leaving the wiring attached.
2. Lubricate the window run channels with MOPAR Silicone Spray Lube, p/n 04318070 or equivalent.
3. Separate the outside mirror from the door, leaving the wiring attached.
4. Install the mirror with washer, p/n 06100876, positioned over the lower rear stud on the mirror (Figure 1). The washer should sit between the gasket and the body of the mirror. Tighten the nuts to 7 Nm (60 in. lbs.).
5. Install the door trim panel.

Tsb 1803604: Dtc p2097 p2099

Service bulletin #: 1803604
replacement sb#:
Nhtsa item #: 10010487
date: 20040903
failing component: 110000 electrical system
make: Dodge
model: Ram
year: 2004
date created: 20041129
description of summary: Malfunction indicator lamp diagnostic trouble code p2097 p2099. *tt

Tsb 1803704: Fuel economy improvement, white smoke on start up, accuracy of fuel mile

Service bulletin #: 1803704
replacement sb#:
Nhtsa item #: 10010488
date: 20040927
failing component: 061000 engine and engine cooling:engine
make: Dodge
model: Ram
year: 2004, 2005
date created: 20041129
description of summary: Fuel economy improvement, white smoke on start up, accuracy of fuel mileage in overhead console display. Flash. *tt

Tsb 1804104: Improved automatic transmission shifting

Service bulletin #: 1804104
replacement sb#:
Nhtsa item #: 10010536
date: 20041025
failing component: 103000 power train:automatic transmission
make: Dodge
model: Ram
year: 2004
date created: 20041130
description of summary: Improved automatic transmission shifting in tow/haul mode. *eh

Tsb 1901204: Steering column snapping or ticking sound

SERVICE BULLETIN #: 1901204
REPLACEMENT SB#: 1900305
NHTSA ITEM #: 10011930
DATE: 20050503
FAILING COMPONENT: 010000 STEERING
MAKE: DODGE
MODEL: RAM
YEAR: 2003, 2004
DATE CREATED: 20050207
DESCRIPTION OF SUMMARY: STEERING COLUMN SNAPPING OR TICKING SOUND. *TT


Parts Required:
Qty. Part No. Description
1 05166528AA Bearing Retainer Kit

Repair Procedure:
WARNING: The steering column bearing retainer is spring loaded and could fly off the
shaft during this repair. Safety glasses should be worn at all times.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIRBAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. THE FASTENERS, SCREWS, AND BOLTS, ORIGINALLY USED FOR THE AIRBAG COMPONENTS, HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANYTIME A NEW FASTENER IS NEEDED, REPLACE WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR FASTENERS LISTED IN THE PARTS BOOKS.
1. Disconnect and isolate the negative battery terminal. Wait at least two minutes for the airbag system capacitor to discharge prior to disassembling the steering column.
NOTE: If you are not familiar with steering column and air bag repair procedures, refer
section 19 of the appropriate Service Manual for detailed procedures and
safety precautions.
2. Remove the drivers air bag, steering wheel, steering column shroud, clock spring and
multifunction switch.
3. Inspect the wave spring under existing retainer (Fig. 1). If spring is fully compressed,
stop this procedure and replace column. If the spring is not fully compressed, proceed to
step 4.
4. With the ignition key removed, rotate steering wheel until it locks (you may have to
reinstall wheel in order to rotate shaft)
5. Remove bearing retainer from shaft if possible by hand, with pliers, or by placing a
screwdriver underneath retainer and prying upward (Fig. 2). If the retainer can be
removed, proceed to step 7. If the retainer will not come off the shaft, continue with step 6.
6. Use a sharp ¼" chisel to score the retainer as shown (Fig. 3). Be careful not to damage any of the surrounding components with chisel. Only apply enough force to score the retainer. Do not attempt to break completely through the retainer with the chisel, this
excessive force will damage the bearings. Remove any material particles that might fall
into the bearing pocket.
7. Insert a screwdriver under retainer (near score mark) and pry the retainer upward until it
breaks. If unsuccessful, re-score the retainer again and try again.
8. Discard old retainer and wave spring. Make sure shaft is pulled upward (toward driver)
as far as possible and the bearing race and wedge are sitting tightly inside of bearing.
9. Install the new wave spring and retainer on wedge on shaft.
10. Check steering column shaft threads by hand tightening installation tool bolt provided in the kit into shaft approximately ½9 and removing. If bolt threads easily into shaft proceed to step 9. If bolt does not thread easily into shaft, re-tap the hole using an M10 x 1.5 tap.
11. Place bearing installation tool onto shaft until it contacts retainer.
12. Insert the bolt into steering column shaft. Hand tighten until threads are fully engaged. Tighten bolt down with 15 mm socket wrench until the tool bottoms out on bearing. You
may hear a clicking noise as the retainer is being pressed down onto the shaft, this is
normal.
13. Remove bolt and tool. Inspect retainer and spring (Fig. 1). The spring should be centered under the retainer and compressed as shown. If the spring is not centered under retainer it may be pushed towards the shaft using a screwdriver (do not damage spring). If spring needs adjusting, repeat step 12 to ensure the retainer is in the correct position.
14. Install the multifunction switch, clock spring, steering column shroud, steering wheel and drivers air bag.
15. Connect the negative battery cable.

Tsb 1901004: Power steering fluid contamination

SERVICE BULLETIN #: 1901004
REPLACEMENT SB#:
NHTSA ITEM #: 10011958
DATE: 20041129
FAILING COMPONENT: 010000 STEERING
MAKE: DODGE
MODEL: RAM 3500
YEAR: 2004
DATE CREATED: 20050208
DESCRIPTION OF SUMMARY: POWER STEERING FLUID CONTAMINATION. *TT


Discussion:
Do not use fluids or supplements that contain Teflon as they will cause a restriction at the filter in the power steering fluid reservoir, causing severe damage to the 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 system. To ensure the performance and durability of Chrysler Group steering systems, use only Mopar Power Steering Fluid +4, ATF+4 Automatic Transmission Fluid, or equivalent (MS-9602), in the power steering system.

Tsb 2300505: Mud or dirt may accumulate on the rocker panel

SERVICE BULLETIN #: 2300505
REPLACEMENT SB#:
NHTSA ITEM #: 10012262
DATE: 20050131
FAILING COMPONENT: 162000 STRUCTURE:BODY
MAKE: DODGE
MODEL: RAM
YEAR: 2003, 2004
DATE CREATED: 20050223
DESCRIPTION OF SUMMARY: MUD OR DIRT MAY ACCUMULATE ON THE ROCKER PANEL CAUSING CUSTOMERS TO COMPLAIN THAT THEIR CLOTHING GETS DIRTY WHEN THEY ENTER OR EXIT THE VEHICLE. *TT


Parts Required:
Qty. Part No. Description
1 55277214AA Lower Door Secondary Seal - Regular Cab - Right
1 55277215AA Lower Door Secondary Seal - Regular Cab - Left
1 55277216AA Lower Door Secondary Seal - Quad Cab - Right Front
1 55277217AA Lower Door Secondary Seal - Quad Cab - Left Front
1 55277218AA Lower Door Secondary Seal - Quad Cab - Right Rear
1 55277219AA Lower Door Secondary Seal - Quad Cab - Left Rear

Repair Procedure:
1. Remove the Lower door secondary seals.
CAUTION: Use caution when drilling the additional fastener holes to prevent damage to the outer door skin. Use a drill stop when performing this operation.
2. The new seal is longer than the original seal, Install the new seal with the two additional fasteners at the front of the door. See the new seal to locate the position of the fastener holes. Mark the hole location and drill the additional holes using a 5 mm (3/16 in.) with a drill stop. Coat the bare metal edges with a corrosion preventing primer and allow the primer to dry.
3. Install the remaining fasteners.
4. Repeat the process for remaining doors.

Tsb 1800405: Erroneous diagnostic trouble codes

Service bulletin #: 1800405
replacement sb#:
Nhtsa item #: 10012325
date: 20050112
failing component: 110000 electrical system
make: Dodge
model: Ram
year: 2004
date created: 20050224
description of summary: Erroneous diagnostic trouble codes. *eh

Tsb 1400205: Inactive throttle body in cold ambient temperatures

Service bulletin #: 1400205
replacement sb#:
Nhtsa item #: 10013705
date: 20050317
failing component: 110000 electrical system
make: Dodge
model: Ram
year: 2003, 2004
date created: 20050425
description of summary: Inactive throttle body in cold ambient temperatures. 2005 dodge ram *sc

Tsb 0801505: Powertrain control module initialization

Service bulletin #: 0801505
replacement sb#:
Nhtsa item #: 10013731
date: 20050302
failing component: 103100 power train:automatic transmission:control module (tcm, pcm)
make: Dodge
model: Ram
year: 2003, 2004
date created: 20050426
description of summary: Powertrain control module initialization. *sc

Tsb 1801305: Idle fluctuation

Service bulletin #: 1801305
replacement sb#: 1801305a
nhtsa item #: 10015058
date: 20050419
failing component: 060000 engine and engine cooling
make: Dodge
model: Ram
year: 2004
date created: 20050517
description of summary: Idle fluctuation/diagnostic trouble codes. *tt

Tsb 1801705: Ctd long crank times below freezing

Service bulletin #: 1801705
replacement sb#:
Nhtsa item #: 10015060
date: 20050421
failing component: 060000 engine and engine cooling
make: Dodge
model: Ram
year: 2003, 2004
date created: 20050517
description of summary: Long crank times in ambient temperatures below freezing. *tt

Tsb 1801605: Throttle body coking

Service bulletin #: 1801605
replacement sb#:
Nhtsa item #: 10015068
date: 20050412
failing component: 180000 vehicle speed control
make: Dodge
model: Ram
year: 2004
date created: 20050517
description of summary: Throttle body coking. *tt

TSB 5002: 3.7L Water Pump

Service bulletin #: 5002
replacement sb#:
Nhtsa item #: 10015075
date: 20050428
failing component: 060000 engine and engine cooling
make: Dodge
model: Ram
year: 2003, 2004
date created: 20050517
description of summary: New water pump for 3.7l engine - no longer common with 4.7l. Advanced service information #05-002. *tt

Tsb 1802705: Dtc p0330, and/or p0740

Service bulletin #: 1802705
replacement sb#:
Nhtsa item #: 10015802
date: 20050604
failing component: 060000 engine and engine cooling
make: Dodge
model: Ram
year: 2004
date created: 20050812
description of summary: All vehicles - evaporative leak detection monitor enhancement; ram quad cabs vehicles have cold start rough idle and malfunction indicator lamp illumination with diagnostic trouble codes p0330, and/or p0740. *tt

Tsb 1400405: Electronic fuel control actuator

Service bulletin #: 1400405
replacement sb#:
Nhtsa item #: 10016020
date: 20050708
failing component: 090000 fuel system, other
make: Dodge
model: Ram
year: 2003, 2004
date created: 20050818
description of summary: Electronic fuel control (efc) actuator available for service. *tt