Side Cover: Service and Repair

TSB NUMBER: 09-002-02

NOTE: THIS BULLETIN APPLIES TO 1998 - 2002 (BR) RAM TRUCKS EQUIPPED WITH THE 24-VALVE CUMMINS DIESEL ENGINE BUILT AFTER MARCH 27,1998.

SYMPTOM/CONDITION:

Owners of 1998 - 2002 (BR) Ram Trucks equipped with the 24-valve Cummins diesel engine may experience engine oil overflow from the front crankcase breather when the vehicle is operated off-road on an extreme downhill grade (37.5% or 22° slope/grade). Operation of this type for extended periods of time can cause enough engine oil depletion to damage the engine. A kit containing all components necessary to eliminate the oil overflow has been made available. If the condition exists perform the repair.

NOTE: IN THE INTEREST OF CUSTOMER SATISFACTION, RECORD SET RADIO STATIONS AND REPROGRAM WHEN PROCEDURE IS COMPLETED.

1. Open the hood.
2. Disconnect both negative battery cables.
3. Remove the air intake connector.
4. Remove the charge air cooler duct.
5. Remove the washer bottle. Service and Repair
6. Remove the fan shroud and viscous fan. Service and Repair
7. Remove the crankcase breather assembly and discard.
8. Remove the fuel filter/water separator assembly. Fuel Filter
9. Remove the VP44 fuel injection pump. Service and Repair
10. Remove the CM551 engine control module. Service and Repair
11. Remove the mounting bolt that secures the fuel line to the tappet cover.
12. Disconnect and remove the fuel line "T' fitting and mounting bracket.
13. Remove the tappet cover mounting bolts and side cover.
14. Install new tappet cover with breather tube. Torque bolts to 24 N.m (17 ft. lbs.)

NOTE: BREATHER TUBE SHOULD BE ROUTED DOWN, BEHIND THE STARTER AND AWAY FROM THE DIFFERENTIAL.

15. Reconnect and install fuel line "T' fitting and mounting bracket.
16. Install the mounting bolt that secures the fuel line to the tappet cover.
17. Install the engine controller.
18. Install the fuel pump.
19. Install the fuel filter/water separator assembly. Service and Repair
20. Install the replacement access plug on the front of the gear cover.
21. Install the fan shroud and viscous fan.
22. Install the washer bottle.
23. Install the charge air cooler duct.
24. Install the air intake connector.
25. Reconnect both negative battery cables.
26. Start the engine and check for leaks.
27. Close the hood and reprogram the radio (if necessary).