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TSB 18-027-03

Flash: No Throttle Response, Lack of Power While Towing and
Diagnostic Trouble Codes (DTC) P2638/P0700

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Date: July 4, 2003

THE MDS2 MUST BE OPERATING WITH CIS CD2137 OR HIGHER, AVAILABLE JULY 21, 2003.

Models: 2003 (DR) Ram Truck

NOTE. THIS BULLETIN APPLIES TO ALL RAM TRUCKS EQUIPPED WITH THE 5.9L CUMMINS 24-VALVE DIESEL ENGINE (SALES CODE ETC OR ETH) BUILT ON OR BEFORE JULY 25, 2003 (MDH 0725XX).

Overview:
This bulletin involves selectively erasing and reprogramming the Cummins CM845 Engine Control Module (ECM) with new software.

Symptom/Condition:
The vehicle may exhibit:

• No throttle response if the engine is started with the Accelerator Pedal Position Sensor (APPS) in an off-idle position (pedal depressed) and the transmission is shifted into drive or reverse while the APPS remains in an off-idle position (pedal depressed), causing the engine to remain at idle,
• Lack of power while towing or hauling a heavy load with the transmission in overdrive - vehicles equipped with 47RE transmission.

Technician may find the following DTC:

P2638 - Torque Management Feedback Performance - vehicles equipped with 48RE Transmissions.

This engine software includes a change to Sentry Key Immobilizer (SKIM) functionality and the APPS auto zero algorithm.

Diagnosis:
Using a Scan Tool (DRBIII) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin.

If the vehicle exhibits any of the Symptom/Conditions, perform the Repair Procedure.

Equipment Required:

NPN	Battery Charger
CH6000A	Scan Tool (DRB III)
CH2002	General Purpose Interface Bus Cable Assembly
CH7000/7001	J1962 Cable
	TechCONNECT Workstation

Parts Required:

Qty.	Part No.	Description
1	04669020	Label,   Authorized Software Update
1	04275086AB	Label,   Authorized Modification

Repair Procedure:

1.    Install a battery charger and verify battery charge is above 11.5 volts.

2.    Connect the DRBIII and the TechCONNECT to the vehicle. Verify "DRBIII Status: Connected".

3.    Verify that the VIN displayed on the screen is correct. If the VIN is not displayed or not correct, manually enter the VIN. select "OK".

4.    Enter the information requested by the "New Session Setup" window. Select "OK".

5.    Select the "Flash" tab.

6.    Select "Use Currently Selected Vehicle".

7.    Select "Update Controller Software".

8.    Monitor the "Status" window on TechCONNECT and follow the instructions.

9.    Follow the instructions on the DRBIII to complete the calibration download process.

10.  For 2003 and later modules, determine if the vehicle is equipped with a SKIM module.

a. If the vehicle is equipped with SKIM, the DRBIII must be used to transfer the VIN and Security Key from the SKIM to the ECM. This is accomplished by selecting "Cummins ECM Replaced" under the "Miscellaneous" section of the "SKIM" menu.

b. If the vehicle is not equipped with SKIM, the VIN must be manually programmed by selecting "CM845 Check VIN" under the "Miscellaneous" section of the "Cummins Controller (ECM/ENGINE)" menu.

NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (TCM, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED.

NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW.

11.    Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay.

FIGURE 1- AUTHORIZED SOFTWARE UPDATE LABEL

 12.  Type the following information on the "Authorized Modification Label" P/N 04275086AB and attach the label near the VECI label.

FIGURE 2 - AUTHORIZED MODIFICATION LABEL 1 - CUMMINS ENGINE CONTROL MODULE P/N (INSERT P/N) USED 2 - CHANGE AUTHORITY: TSB XX-XXX-XX 3 - DEALER CODE: XXXXX 4 - DATE: XX-XX-XX

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:

Labor Operation No:  08-19-36-94  Preprogram Powertrain Control Module ....................0.5 Hrs.

Failure Code:

This page was edited on: May 3, 2004