TSB 06-001-07: Clutch System May Over-Adjust Causing Difficulty Engaging

[DOF Info]

Date: February 03, 2007   

Models: 2007 (D1/DH/DC) Ram Truck (2500/3500)

NOTE: This bulletin applies to vehicles equipped with a 5.9L or 6.7L Cummins turbo-diesel engine and the G56 manual transmission (sales code ETH, ETJ, and DEG respectively), and built on or before November 09, 2006 (MDH 1109XX).

Overview:
This bulletin involves replacement of the clutch system flywheel, pressure plate, and disc.

Symptom/Condition:
The customer may experience difficulty attempting to engage a manual transmission gear. This may be due to the self-adjusting mechanism in the clutch system. The self-adjusting clutch mechanism may over-adjust (forward adjust). This condition most often will occur within the first 1,000 miles of vehicle operation.

Diagnosis:
1. Inspect the clutch hydraulic system for leaks and or low fluid.
2. Is there a clutch system hydraulic leak and/or is the hydraulic fluid level low?
    a. If YES >>> then repair the clutch hydraulic system. Proceed to the next step.
    b. If NO >>> then proceed to the next step.
3. Evaluate the shift efforts of 1st gear when the engine is off and when the engine is running.
    a. With the engine off and the clutch pedal fully depressed (pushed down) attempt to shift into 1st gear.
    b. With the transmission in neutral, parking brake firmly set, start the engine and allow to idle.
    c. With the engine running, service brake fully applied, and the clutch pedal fully depressed (pushed down) attempt to shift into 1st gear.
4. When attempting to engage 1st gear, is the shift effort substantially higher (more difficult or unable to engage 1st gear) when the engine is running, than when the engine is off?
    a. If YES >>> then perform the Repair Procedure
    b. If NO >>> then proceed to the next step.
5. Evaluate the shift efforts of Reverse gear when the engine is off and when the engine is running.
    a. With the engine off and the clutch pedal fully depressed (pushed down) attempt to shift into Reverse gear.
    b. With the transmission in neutral, parking brake firmly set, start the engine and allow to idle.
    c. With the engine running, service brake fully applied, and the clutch pedal fully depressed (pushed down) attempt to shift into Reverse gear.
6. When attempting to engage Reverse gear, is the shift effort substantially higher (more difficult or unable to engage Reverse gear) when the engine is running, than when the engine is off?
    a. If YES >>> then perform the Repair Procedure.
    b. If NO >>> then this Bulletin does not apply. Further diagnosis is required.

Parts Required:
Qty.    Part No.            Description
1    52104721AF    Flywheel, Engine Dual Mass
1    52104724AD    Kit, Clutch (includes: Clutch Disc and Pressure Plate)
8    06036096AA    Bolts (Flywheel to Pressure Plate)

Repair Procedure:
NOTE: When the clutch pressure plate over-adjusts, the plate diaphragm fingers appear to be flat (collapsed) and marks on the clutch disc will be present due to contact with the collapsed plate diaphragm fingers.
1. Replace the dual mass flywheel, pressure plate, clutch disc, and plate attaching bolts. Refer to TechCONNECT for detailed service repair procedures. From TechCONNECT select: the 'Service Info" tab and enter vehicle information (year, model, and engine). Select: 6 - Clutch > Flywheel and Disc - Clutch > Removal, Installation, and Adjustments.

Policy:    Reimbursable within the provisions of the warranty.


Failure Code:
ZZ           Service Action