Crossmember/Transmission Mount - Vibration
NO: 23-48-96GROUP: Body
DATE: Aug. 9, 1996
SUBJECT:
Vibration Felt In Seat
On Smooth Road
MODELS:
1995-1996 (BR) Ram Truck
NOTE:
THIS BULLETIN APPLIES TO CLUB CAB TRUCKS BUILT BEFORE MARCH 15, 1996 (MDH 03-15-XX).
SYMPTOM/CONDITION:
Vibrations felt through the seat when traveling at varying speeds on a smooth road surface.
PARTS REQUIRED:
1 4856676 W Shaped Reinforcement
14 6034573 1/4" x .502" Rivets
15 6033688 1/4" x .553" Rivets
6 6501557 Cab Chassis Bolts
1 82300234 RTV Sealant
1 52022062 Cushion, Rear Transmission Mount (1995 Model Year Only)
REPAIR PROCEDURE:
This bulletin involves the addition of a reinforcement over the existing cab crossmember on all affected vehicles. A revised rear transmission mount cushion will be installed on 1995 vehicles, with the exception of those equipped with a Diesel engine.
REAR TRANSMISSION MOUNT CUSHION INSTALLATION (1995 VEHICLES EQUIPPED WITH GASOLINE ENGINES ONLY)
1. Raise transmission slightly with service jack to relieve load on crossmember, bracket and cushion.
2. Remove two nuts from studs holding cushion to crossmember.
3. Raise transmission with jack until studs from cushion clear the top of the crossmember.
4. Remove two bolts holding cushion to mounting bracket and remove cushion.
5. Install cushion (P/N 52022062) and attach to mounting bracket using bolts from step 4 and torque to 45 Nm (35 ft. lbs).
6. Lower transmission all the way, making sure studs from cushion align in slots of crossmember.
7. Secure cushion to crossmember using nuts from step 2 and torque to 45 Nm (35 ft. lbs).
CROSSMEMBER REINFORCEMENT (ALL VEHICLES)
1. Raise the vehicle on an appropriate lift.
2. Remove the 4 rear cab chassis bolts holding the cab to the frame and discard them. Loosen the front 2 cab chassis bolts, but DO NOT remove them.
3. Using a suitable lifting device, such as a 6 foot jack stand, push up on the rear of the cab until it is approximately 6" off the frame.
4. Remove vapor canister, if equipped, from frame rail on drivers side.
5. Remove the heat shield that goes over the front seat reinforcement by removing the three nuts.
6. Position the W-shaped reinforcement over the current front seat reinforcement. The side with the large indentation goes toward the front of the vehicle.
7. Clamp the W-shaped reinforcement to the front seat reinforcement in the midsection. Make sure that the W-shaped reinforcement fits tightly to the cab underside.
8. Drill the first of two 1/4" (6.33 mm) holes in the center of the two reinforcements. (Figure 1 - Identification B1)
9. Apply RTV sealant (P/N 82300234) to the holes drilled in step 7 and install a 1/4" x 0.553" rivet (P/N 6033688). Complete the procedure by installing the other 2 rivets in the center section.
10. Fabricate a drill stop sleeve from 5/16" copper tubing. Cut the tubing so that when the 1/4" drill is chucked in the drill motor, there will only be 5 mm (3/16") of the bit exposed.
CAUTION:
THE SLEEVE MUST BE USED AS A DRILL STOP FOR THE REMAINING HOLES THAT ARE TO BE DRILLED THAT USE THE 1/4" X 0.553" RIVET (IDENTIFICATION "B" ON FIGURE 1). IF IT IS NOT USED THE CARPET IN THE CAB WILL BE DAMAGED.
11. With the drill stop in place, drill the first of six 1/4" holes around the seat attachment bolt on the passenger side of the cab (Figure 1 - Identification B2).
12. Apply RTV sealant (P/N 82300234) to the first hole and install a 1/4" x 0.553" rivet (P/N 6033688). Complete this step by drilling, applying sealant, and installing one rivet at a time for the remaining five holes.
13. With the drill stop in place, drill the first of six 1/4" holes around the seat attachment bolt on the drivers side of the cab (Figure 1 - Identification B3).
14. Apply the sealant to the first hole and install a 1/4" X 0.553" rivet (P/N 6033688). Complete this step by drilling, applying sealant, and installing one rivet at a time for the remaining five holes.
15. Fabricate a second tubing (5/16" copper) so that when the drill bit is chucked in the drill motor, there will only be 3 mm (1/8") of the bit exposed. Use this drill stop for the remaining holes.
16. With the second drill stop (3 mm or 1/8") in place, drill the first of seven 1/4" holes around the perimeter of the W-shaped reinforcement on the passenger side of the cab (Figure 1 - Identification Al).
17. Apply sealant to the first hole and install a 1/4" X 0.502" rivet (P/N 6034573). Complete this step by drilling, applying sealant, and installing one rivet at a time for the remaining six holes.
18. With the second drill stop (3 mm or 1/8") in place, drill the first of seven 1/4" holes around the perimeter of the W-shaped reinforcement on the drivers side of the cab Figure 1 - Identification A2).
19. Apply sealant to the first hole and install a 1/4" X 0.502" rivet (P/N 6034573). Complete this step by drilling, applying sealant, and installing one rivet at a time for the remaining six holes.
20. Apply a 1/4" bead of RTV sealant (P/N 82300234) to the W-shaped reinforcement where the heat shield mates to it to prevent rattling.
21. Install the heat shield in the same position as it was removed from.
22. Install vapor canister.
23. Lower the cab.
CAUTION:
NEW CAB CHASSIS BOLTS (PIN 6501557) MUST BE USED WHEN INSTALLING THE CAB.
24. Install new cab bolts (P/N 6501557) in the 4 rear cab chassis mounts and torque to 80 Nm (60 ft-lbs). Refer to page 13-22 of the 1995 Ram Truck Service Manual (Publication No. 81-370-5108) for further information if needed.
25. Remove and discard the front 2 cab chassis bolts and replace them with 2 new bolts (P/N 6501557) and torque to 80 Nm (60 ft-lbs).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 13-01-00-92 2.2 Hrs.
FAILURE CODE: P8 - New Part