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Discussion Starter · #1 · (Edited)
NUMBER: 21-002-07 REV. A
GROUP: Transmission
DATE: February 10, 2007


THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-002-07, DATED
JANUARY 31, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A PART
NUMBER CORRECTION.

THE StarSCAN® FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM
THE INTERNET.

StarSCAN® SOFTWARE LEVEL MUST BE AT RELEASE 7.03 OR HIGHER.

StarMOBILE STANDALONE DOES NOT SUPPORT THIS SERVICE ACTION.

SUBJECT:

Flash: Torque Converter Shudder / Shift Quality Improvements / DTC P0732

OVERVIEW:

This bulletin involves reprogramming the Powertrain Control Module (PCM) with new
software and replacing the torque converter as required.

MODELS:
2007 (CS) Pacifica
2007 (DR) Ram 1500
2007 (HB) Durango
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (KJ) Liberty
2007 (LE) 300C/300 Touring (International Markets)
2007 (LX) 300/Magnum/Charger
2007 (ND) Dakota

NOTE: This bulletin applies to CS/DR/HB/JK/JS/KA/KJ/LE/LX models built with a
41TE, 42RLE, or 62TE automatic transmission (Sales Codes DFF, DGV, or
DG2). built on or before December 15, 2006 (MDH1215XX) and ND models
with 42RLE built on or before January 2, 2007 (MDH0102XX).



21-002-07 REV. A -2


NOTE: This bulletin DOES NOT apply to JS models with a 2.4L engine.

SYMPTOM/CONDITION:

The vehicle operator may experience one or more of the following symptoms:

1. Transmission Shudder -42RLE All, 41TE CS/JS, 62TE CS/JS
a. This condition can only occur after the vehicle has been driven and the torque
convertor is past the break in period. Torque Converter break in can be confirmed
with the StarSCAN®.
b. If experienced, the shudder may occur when the transmission temperature is
between 38° C and 54° C (100° F and 130° F) during steady state driving with the
torque convertor in partial lock (EMCC) operation. The shudder feels like the vehicle
is being driven over rumble strips.
2. Torque Converter Pull In Bump -41TE JS, 62TE CS/JS
a. This condition can occur due to abrupt torque converter clutch engagement during
EMCC initialization.
3. DTC P0732 -Gear Ratio Error in 2nd Gear -62TE CS
a. The MIL may or may not be lit (2 trip fault).
b. Limp In will occur when this fault is set.
c. This is an intermittent condition and cannot be duplicated. If the fault can be
duplicated, other conditions exist and further investigation will be required.
4. Shift Quality Improvements -62TE CS
a. Rapid Decel Coastdown Stumble.
b. Low Speed 3-2 Kickdown Harshness.
c. 4-5 and/or 5-6 upshift flare bump.
DIAGNOSIS:

Using a Scan Tool (StarSCAN®) with the appropriate Diagnostic Procedures available in
TechCONNECT, verify all engine/transmission systems are functioning as designed. If
DTC's other than those listed above are present record them on the repair order and repair
as necessary before proceeding further with this bulletin.

If the vehicle operator describes the Symptom/Conditions and they can be verified,
perform the appropriate Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description
1 04275086AB Label, Authorized Modification
AR(1) 05175001AA Torque Converter, (42RLE) 2.7L LX/LE -3.7L Truck 3.7/
3.8L Jeep
AR(1) **68006834AA** Torque Converter, (41TE) 3.8L CS
AR(1) 68103527AB Torque Converter, (41TE) 2.7L JS
AR(1) 68003520AB Torque Converter, (62TE) 4.0L CS -3.5L JS


-3- 21-002-07 REV. A

SPECIAL TOOLS / EQUIPMENT REQUIRED:

NPN Battery Charger
CH9401 StarSCAN® Tool
CH9404 StarSCAN® Vehicle Cable
CH9409 StarSCAN® Documentation Kit
CH9410 StarSCAN® Ethernet Cable, 12 ft.
CH9412 StarSCAN® Software Update Device Kit
TechCONNECT PC or equivalent

REPAIR PROCEDURES BY SYMPTOM/CONDITION:

SYMPTOM/CONDITION 1 -Transmission Shudder -42RLE All, 41TE CS/JS, 62TE
CS/JS:

1. Replace the Torque Converter -Use the appropriate part number listed in the parts
table above -Follow detailed service procedures listed in
DealerCONNECT>TechCONNECT for Torque Converter replacement.
2. Reprogram the PCM with the latest software using the flash procedure listed in the
flash procedure below. After PCM reprogramming, the following must be performed:
a. Clear the Variable Line Pressure (VLP) Counters, found in the StarSCAN® Misc
Function Menu. VLP Clear Counters must be completed on all models with a 62TE
transmission or if DTC P1745 appears on other transmission applications.
b. Clear any DTC's that may have been set in other modules due to reprogramming.
c. Perform the Quick Learn function, found in the StarSCAN® Misc Function Menu.
d. Select the TCC Break In, found in the StarSCAN® Misc Function Menu and select
“Start TCC Break In”.
SYMPTOM/CONDITION 2 -Torque Converter Pull In Bump -41TE JS, 62TE CS/JS:

1. Replace the Torque Converter -Use the appropriate part number listed in the parts
table above -Follow detailed service procedures listed in
DealerCONNECT>TechCONNECT for Torque Converter replacement.
2. Reprogram the PCM with the latest software using the flash procedure listed in the
flash procedure below. After PCM reprogramming:
a. Clear the Variable Line Pressure (VLP) Counters, found in the StarSCAN® Misc
Function Menu. VLP Clear Counters must be completed on all models with a 62TE
transmission or if DTC P1745 appears on other transmission applications.
b. Clear any DTC's that may have been set in other modules due to reprogramming.
c. Perform the Quick Learn function, found in the StarSCAN® Misc Function Menu.
d. Select the TCC Break In, found in the StarSCAN® Misc Function Menu and select
“Start TCC Break In”.
SYMPTOM/CONDITION 3 -DTC P0732 -62TE CS:

1. Reprogram the PCM with the latest software using the flash procedure listed in the
flash procedure below. After PCM reprogramming, the following must be performed:
a. Clear the Variable Line Pressure (VLP) Counters, found in the StarSCAN® Misc
Function Menu. VLP Clear Counters must be completed on all models with a 62TE
transmission.
b. Clear any DTC's that may have been set in other modules due to reprogramming.
c. Perform the Quick Learn function, found in the StarSCAN® Misc Function Menu.

21-002-07 REV. A -4


SYMPTOM/CONDITION 4 -Shift Quality Improvement -62TE CS:

1. Reprogram the PCM with the latest software using the flash procedure listed in the
flash procedure below. After PCM reprogramming, the following must be performed:
a. Clear the Variable Line Pressure (VLP) Counters, found in the StarSCAN® Misc
Function Menu. VLP Clear Counters must be completed on all models with a 62TE
transmission.
b. Clear any DTC's that may have been set in other modules due to reprogramming.
c. Perform the Quick Learn function, found in the StarSCAN® Misc Function Menu.
FLASH REPAIR PROCEDURE -USING THE INTERNET TO RETRIEVE THE FLASH
FILE:

NOTE: When performing this Repair Procedure, the software release level in the
StarSCAN®; must be programmed with 7.03 level software or higher. The
software release level is visible in the blue header at the top of the
StarSCAN® screen.

NOTE: The StarSCAN® diagnostic scan tool fully supports Internet connectivity.
However, to take advantage of this feature you must first configure the
StarSCAN® for your dealership's network. Make sure the StarSCAN® is
configured to the dealership's network before proceeding. For instruction on
setting up your StarSCAN® for the dealer's network refer to either:
“DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online
Documentation”, or refer to the StarSCAN® Quick Start Networking Guide.
The StarSCAN® Quick Start Networking Guide is also available on the
www.dcctools.com website under the "Download Center".

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

1. Install a battery charger and verify that the charging rate provides approximately 13.5
volts. Set the battery charger to continuous charge. Do not allow the charger to time
out during the flash process. Remove the charger from the battery when the flash
process is complete.
2. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN® and the dealer's
network drop.
3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle.
4. Power ON the StarSCAN®.
5. Retrieve the old PCM part number. Using the StarSCAN® at the “Home” screen:
a. Select “ECU View”
b. Touch the screen to highlight the PCM in the list of modules.
c. Select “More Options”
d. Select “ECU Flash”
e. Record the part number at the top of the “Flash PCM” screen for later reference.
f. Select “Browse for New File”. Follow the on screen instructions.
g. Select “Download to Scantool”.
h. Select “Close” after the download is complete, then select “Back”.
i. Highlight the listed calibration.
j. Select “Update Controller”. Follow on screen instructions.
k. When the update is complete, select “OK”.
l. Verify the part number at the top of the “Flash PCM” screen has updated to the new
part number.

-5- 21-002-07 REV. A


6. After flash reprogramming, be sure to Perform the additional Repair Steps
associated with each procedure. These steps may include VLP clear counters, Quick
Learn and/or Re-enable TCC break in. It is important to perform these additional steps
in the order listed for each repair.
NOTE: Due to the PCM programming procedure, a DTC may be set in other modules
(TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some
DTC's may cause the MIL to illuminate. From the “Home” screen select
“System View”. Then select “All DTCs”. Press “Clear All Stored DTCs” if
there are any DTCs shown on the list.

NOTE: The following step is required by law when reprogramming a PCM and/or
TCM.

7. Type the necessary information on the “Authorized Modification Label” p/n
04275086AB and attach near the VECI label (Fig. 1).
Fig. 1 AUTHORIZED MODIFICATION LABEL

1 -POWERTRAIN CONTROL MODULE P/N (INSERT P/N) USED
2 -CHANGE AUTHORITY: TSB XX-XXX-XX
3 -DEALER CODE: XXXXX
4 -DATE: XX-XX-XX


21-002-07 REV. A -6


POLICY:

Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount
21-33-01-90 Torque Converter, Transmission Replace,
PCM -Reprogram -41TE
Equipped Vehicles (B)
CS 5.9 Hrs.
JS 5.1 Hrs.
21-33-01-91 Torque Converter -Transmission Replace
& Reprogram PCM -62TE
Equipped (B)
CS 8.1 Hrs.
JS 5.4 Hrs.
21-33-01-92 Torque Converter, Transmission Replace,
PCM -Reprogram -62TE AWD
Equipped Vehicles (B)
CS 8.6 Hrs.
21-33-01-93 Torque Converter, Transmission Replace,
PCM -Reprogram -42RLE
Equipped Vehicles (B)
DR 3.3 Hrs.
HB 3.6 Hrs.
JK 1.9 Hrs.
KA 3.4 Hrs.
KJ 2.7 Hrs.
LE/LX 5.0 Hrs.
ND 3.1 Hrs.
21-33-01-96 Torque Converter, Transmission Replace,
PCM -Reprogram -42RLE 4X4
Equipped Vehicles (B)
JK 2.5 Hrs.
KA 3.9 Hrs.
KJ 3.5 Hrs.
ND 4.1 Hrs.
18-19-06-44 Module, Powertrain Control Module (PCM)
-Reprogram -ONLY (B)
0.4 Hrs.

FAILURE CODE:


ZZ Service Action
 

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Much Thanks. I picked up my SLT the other day and yesterday while hitting around 45-50 mph I did notice the shudder as described :(
Just notified the dealer.
 

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Discussion Starter · #5 · (Edited)
Hey Dan,

I have not changed out my torque converter. I let the break-in run its course and the shudder is 95% gone as compared to before. I curious to see what this new TSB does.

I was going to perform this TSB today only to find out that the Starscan wasn't at the required software level. The TSB requires 7.03 or later and the scanner was only at 7.02 SP3. I was unable to update the Starscan for some stupid reason so the TSB wasn't performed. It may be a few days before the Starscan update is made available. I'll keep checking next week.
 

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Larry, my nitro is going in tomorrow for the torgue converter, I also have a copy of TSB 21-002-07 my main complaint is the surging between 42 and 55 mph. I sure hope they get this thing right, i still love the nitro and am going to drive to florida the end of the month, so dodge get it fixed Les
 

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Les,
I know you have been waiting for a good while for your tq.converter to come in.
Because of that, I would Make Sure the dealer checks the tq. converters part # he has for you - with the new Bullitens part # Just to be sure that it's the same.
Good Luck,
Frank
 

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I'm taking my SLT in for the third TSB re-program... can anyone tell me if there is any damage being done to the torque converter or transmission from having the wrong programing from the start?

Everytime they re-programmed it and put it in to re-learn mode it worked great for a while... each time it seems to be getting worse.

Love the Nitro... unfortunately I got mine too soon :( - manufactured 10/06
 

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Okay guys, took mine in for TSB 21-002-07 this morning. Service told me it may take a couple of days before I get my baby back. I told them I wouldn't even call, just get it right and call me when you think you've done so. Will keep everyone posted.
 

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Larry, and all concerened, got my nitro back tonight, new torgue converter, did the flash, relocate coolant bottle vent hole[was a bulletin] fixed surge
[cause internal Defact ?] rapid reponse [inoperative door locks] rapid reponse
[flash HVAC control]. Seems to have corrected all problems, runs sweet, I only hope everything stays good. So guys and girls stay with the nitro things can get straighten out Les
 
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