Engine/Transmission Controls - Surge After A/T Lock-Up
NUMBER: 18-023-04GROUP: Vehicle Performance
DATE: May 18, 2004
THE SOFTWARE FOR THE DRB Ill� WILL BE AVAILABLE ON DealerCONNECT MAY 18, 2004.
FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2004.
SUBJECT:
Surge With Transmission at Full Lock-up
OVERVIEW:
This bulletin involves replacing the Powertrain Control Module (PCM) and flashing the TCM with updated software.
MODELS:
2001 - 2002 (RS) Town & Country/Caravan/Voyager
NOTE:
This bulletin applies to RS vehicles equipped with a 3.3L or 3.8L engine (sales code EGA, EGH or EGM) and a EGR valve. EGR valves were installed on all 2001 models and some 2002 models.
SYMPTOM/CONDITION:
The vehicle operator may experience a surge. This conditions is more noticeable at 40 - 50 mph with the transmission in full lock-up on a slight incline under heavy load.
DIAGNOSIS:
Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin.
If the customer describes the Symptom/Condition perform the Repair Procedure.
CAUTION:
These service only PCM's and TCM flash should only be installed to fix this exact condition. This PCM and TCM flash should not be installed for any other purpose.
PARTS REQUIRED:
NOTE:
Prior approval is required through the STAR center before ordering parts and completing repair.
SPECIAL TOOLS/EQUIPMENT REQUIRED:
NOTE:
An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed.
REPAIR PROCEDURE:
1. Replace the PCM with the part number from the table above. Refer to the service information available in TechCONNECT.
NOTE:
Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available.
NOTE:
If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R).
2. Before beginning the TCM reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU:
a. Simultaneously press the "MORE" and "YES" keys.
b. A screen will appear requesting a "COLD BOOT".
c. Follow the on screen instructions by selecting the "F4" key.
d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 3.
3. With the ignition switch in the "RUN" position, determine the original part number of the TCM currently in the vehicle. Using the DRBIII(R) select:
a. "DRBIII(R) Standalone"
b. "1998 - 2004 Diagnostics"
c. "All (Except Below)"
d. "Transmission"
e. "Module Display"
f. Record the "TCM part # " on the repair order for later reference.
4. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen.
5. Enter the "TCM part # " recorded in Step # 3 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration.
6. Select the calibration.
7. Select the "DRBIII(R)" radio button which is next to the "Download/Update" button.
8. Select the "Download/Update" button.
9. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 10.
10. Disconnect the DRBIII(R) from TechCONNECT.
11. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts.
12. Connect the DRBIII(R) to the vehicle.
13. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select:
a. "Vehicle Flash"
b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 14.
NOTE:
Due to the TCM programming procedure, a DTC may be set in other modules (PCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased.
14. With the DRBIII(R) perform the TCM Quicklearn procedure.
NOTE:
The following step is required by law.
15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. (Fig. 1)
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.