IT IS RECOMMENDED THAT SPECIAL TOOL OT38793 (ELECTRONIC VIBRATION ANALYZER) BE USED TO HELP PINPOINT THE ROOT CAUSE OF THE VIBRATION.

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NUMBER: 03-02-99 GROUP: Axles And Propshafts DATE: Mar. 26, 1999 This bulletin is supplied as technical information only and is not an authorization for repair.

1 NUMBER: GROUP: Axles And Propshafts DATE: Mar. 26, 1999 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without written permission of DaimlerChrysler Corporation. SUBJECT: High-Speed Driveline Vibration OVERVIEW: This bulletin involves installing a new propshaft, transmission extension housing seal, indexing the new propshaft, and on some vehicles, replacing the transmission extension housing. MODELS: (AN) Dakota THIS BULLETIN APPLIES TO CLUB CAB R/T VEHICLES EQUIPPED WITH THE 5.9L ENGINE AND AN AUTOMATIC TRANSMISSION BUILT BEFORE OCTOBER 2, 1998 (MDH 1002XX). SYMPTOM/CONDITION: High-speed driveline vibration. DIAGNOSIS: 1. Place the vehicle on a hoist. 2. Simulate curb height by supporting the rear axle with safety stands. 3. Remove the rear tire/wheel assembles 4. Turn the lug nuts around and install the lug onto the wheel studs so that the tapered portion of the lug nut faces outward, then tighten the lug nuts against the brake drum. 5. Start the engine, place the transmission gear selector into DRIVE, and then accelerate until the driveline vibration can be confirmed. Note the vehicle speed at which the vibration occurs. IT IS RECOMMENDED THAT SPECIAL TOOL OT38793 (ELECTRONIC VIBRATION ANALYZER) BE USED TO HELP PINPOINT THE ROOT CAUSE OF THE VIBRATION. 6. If the vibration starts to occur at 128 kph (80 mph) or higher, perform the Repair Procedure. If the vibration occurs at a lower speed, further diagnosis is required. If the vibration is gone, tire/wheel balance is required. Form TSB-003 Rev. 1.05

2 PARTS REQUIRED: AA Propshaft, Aluminum Graphite Seal, Transmission Output Shaft AR (1) AA Housing, Transmission Extension AR (1) Gasket, Bearing Snap Ring Access Hole Cover AR (1) Thrust Plate, Overdrive Piston, in. AR (1) Thrust Plate, Overdrive Piston, in. AR (1) Thrust Plate, Overdrive Piston, in. AR (1) Thrust Plate, Overdrive Piston, in. AR (1) Thrust Plate, Overdrive Piston, in. AR (1) Thrust Plate, Overdrive Piston, in. AR (1) Thrust Plate, Overdrive Piston, in. AR (1) Thrust Plate, Overdrive Piston, in. AR (1) Thrust Plate, Overdrive Piston, in. AR (1) Thrust Plate, Overdrive Piston, in. AR (1) Spacer, Intermediate Shaft End Play, in. AR (1) Spacer, Intermediate Shaft End Play, in. AR (1) Spacer, Intermediate Shaft End Play, in. AR (1) Spacer, Intermediate Shaft End Play, in. AR (1) AA ATF+3 Automatic Transmission Fluid REPAIR PROCEDURE: 1. Raise and support the vehicle on safety stands. 2. Shift the transmission to the NEUTRAL position. 3. Remove the bolts holding the universal joint clamps to the pinion yoke. 4. Slide the slip yoke off of the transmission output shaft and remove the propeller shaft. 5. Remove the transmission extension housing yoke seal. 6. Inspect the extension housing bushing. If the bushing has slid rearward, proceed to the next step. If the bushing is in its original position, proceed to Step Replace the transmission extension housing with p/n AA. Follow the procedures identified in the 1999 Dakota Service Manual (Publication No ), pages through to transfer the components from the old transmission extension housing to the new one. 8. Install new transmission extension housing seal p/n into the extension housing using Special Tool C-3995-A (seal installer) (Figure 1). FIGURE 1

3 THE NEXT STEPS OF THE PROCEDURE WILL ALLOW FOR INDEXING OF THE NEW PROPELLER SHAFT. 9. Using a paint pen or equivalent, place four marks, equally spaced (0 o, 90 o, 180 o, and 270 o positions) on the vibration dampener of the new propeller shaft p/n AA. Then, number the marks 1 through 4 in order. 10. With the number 1 identification mark facing straight down, slide the slip yoke of the new propeller shaft onto the transmission output shaft. 11. Position the universal joint into the axle yoke. Install the universal joint strap and 12. Using a paint pen or equivalent, place a line across the axle pinion yoke and the propeller shaft yoke for installation reference later in the procedure (Figure 2). FIGURE Start the engine, place the transmission gear selector into DRIVE, and then SLOWLY accelerate until maximum driveline vibration has been identified. Note the vehicle speed at which the vibration occurs and the amplitude of the vibration. IT IS RECOMMENDED THAT SPECIAL TOOL OT38793 (ELECTRONIC VIBRATION ANALYZER) BE USED TO HELP IDENTIFY THE AMPLITUDE OF DRIVELINE VIBRATIONS 14. Remove the bolts holding the universal joint clamps to the pinion yoke. 15. Rotate the propeller shaft until the number 1 is facing straight down. 16. Carefully slide the propeller shaft away from the transmission output shaft. Rotate the propeller shaft 90 o until the number 2 is facing straight down. Then, slide the slip 17. Position the universal joint into the axle yoke. Install the universal joint strap and Form TSB-006 Rev. 1.03

4 Repeat Step 13 noting whether or not the vibration increased or decreased. 19. Remove the bolts holding the universal joint clamps to the pinion yoke. 20. Rotate the propeller shaft until the number 2 is facing straight down. 21. Carefully slide the propeller shaft away from the transmission output shaft. Rotate the propeller shaft 90 o until the number 3 is facing straight down. Then, slide the slip 22. Position the universal joint into the axle yoke. Install the universal joint strap and 23. Repeat Step 13 noting whether or not the vibration increased or decreased. 24. Remove the bolts holding the universal joint clamps to the pinion yoke. 25. Rotate the propeller shaft until the number 3 is facing straight down. 26. Carefully slide the propeller shaft away from the transmission output shaft. Rotate the propeller shaft 90 o until the number 4 is facing straight down. Then, slide the slip 27. Position the universal joint into the axle yoke. Install the universal joint strap and 28. Repeat Step 13 noting whether or not the vibration increased or decreased. 29. After evaluating all four indexed positions, phase the propeller shaft to the position that produced the lowest vibration amplitude. The vibration can be fine tuned by rotating the propshaft clockwise or counterclockwise one spline at a time. 30. Once the optimum position between the transmission and propeller shaft has been determined, the propeller shaft must be indexed at the pinion yoke end. Remove the bolts holding the universal clamps to the pinion yoke and rotate the propshaft 180 o from the scribed mark made in Step 12. DO NOT SEPARATE THE PROPSHAFT FROM THE TRANSMISSION OUTPUT SHAFT. 31. Position the universal joint into the axle yoke. Install the universal joint strap and 32. Repeat Step 13 again noting whether or not the vibration increased or decreased.

5 If the peak vibration amplitudes decrease, the propshaft is indexed. If the peak vibration amplitudes increase, return the axle end of the propshaft to its original position. 34. Install the tire/wheel assemblies. 35. Remove the safety stands and lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Inspect Transmission Extension Housing Bushing, Replace Seal, And Index Propeller Shaft Hrs Replace Transmission Extension Housing And Index Propeller Shaft Hrs. FAILURE CODE: P8 - New Part Form TSB-006 Rev. 1.03

NOTE: PERFORM THE PARKING BRAKE CABLE INSPECTION ON BOTH RIGHT AND LEFT REAR PARKING BRAKE CABLES.

NOTE: PERFORM THE PARKING BRAKE CABLE INSPECTION ON BOTH RIGHT AND LEFT REAR PARKING BRAKE CABLES. NUMBER: 05-002-01 GROUP: Brakes DATE: Mar. 9, 2001 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored