THE SOFTWARE FOR StarSCAN VIA THE INTERNET AND DRBIII WILL BE AVAILABLE ON DealerCONNECT MAY 25, 2004.

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1 NUMBER: GROUP: REV. A Vehicle Performance DATE: May 25, 2004 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. THIS BULLETIN SUPERSEDES SERVICE BULLETIN , DATED APRIL 06, ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODELS. THE SOFTWARE FOR StarSCAN VIA THE INTERNET AND DRBIII WILL BE AVAILABLE ON DealerCONNECT MAY 25, THE SOFTWARE WILL ALSO BE AVAILABLE ON A StarSCAN SOFTWARE UPDATE CD RELEASE 4.07 JUNE 28, FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, SUBJECT: Flash: 42RLE Slow or Harsh Gear Engagement After Initial Cold Start OVERVIEW: This bulletin involves selectively erasing and reprogramming with new software the Powertrain Control Module (PCM), or for the Wrangler the Transmission Control Module (TCM). MODELS: **2004 (AN) Dakota** **2004 (HB) Durango** 2004 (KJ) Liberty / Cherokee **2004 (TJ) Wrangler** This bulletin applies to vehicles equipped with a 42RLE automatic transmission (sales code DG6) and built prior to the following dates for each respective model: Dakota (AN) built prior to April 23, 2004 (MDH 0423XX), Durango (HB) built prior to June 30, 2004 (MDH 0630XX), Liberty/Cherokee (KJ) built prior to April 01, 2004 (MDH 0401XX), or Wrangler (TJ) built prior to April 21, 2004 (MDH 0420XX). SYMPTOM/CONDITION: The customer may experience a delayed or slow engagement into gear condition following an initial start in cold weather. This condition will most likely occur after the vehicle has been allowed to cold soak in ambient temperatures of 10 C (50 F) or less. This condition may be experienced after either Reverse or Drive shift position is selected. Form TSB-003 Rev. 1.07

2 REV. A -2- It may take up to three (3) seconds before full transmission gear engagement will occur. During this time, if the accelerator pedal is depressed a harsh engagement may be experienced by the customer as the transmission fully engages. New transmission software has been released to address the above conditions. DIAGNOSIS: Using the appropriate Scan Tool (DRBIII or StarSCAN ) for the vehicle being diagnosed along with TechCONNECT or the appropriate Diagnostic Procedures Manual, 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. The condition of slow or harsh gear engagement that is addressed by the new transmission software may be similar to conditions that may be caused by transmission hardware components. Torque converter fluid drain back or loss of transmission oil pump prime (code 35) are possible examples of hardware components that may also cause slow or harsh gear engagement. If 42RLE transmission hardware or software is suspect it is preferred and recommended that the transmission software be reprogrammed first and then correction of the condition verified prior to performing any major hardware repairs to the transmission. If the vehicle operator describes or experiences the above condition(s) perform the Repair Procedure. PARTS REQUIRED: Qty. Part No. Description AB Label, Authorized Modification SPECIAL TOOLS / EQUIPMENT REQUIRED: For AN, KJ, or TJ Vehicles: NPN Battery Charger CH2002 General Purpose Interface Bus Cable Assembly CH6000A Scan Tool (DRBIII ) CH7000A J1962 Cable with red DRBIII connector TechCONNECT PC An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII connection. Use this cable whenever a flash is being performed.

3 REV. A For HB Vehicles: NPN CH9401 CH9404 CH9409 CH9412 Battery Charger StarSCAN Tool StarSCAN Vehicle Cable StarSCAN Documentation Kit StarSCAN Software Update Device Kit TechCONNECT PC or equivalent StarSCAN Software Update CD REPAIR PROCEDURE FOR AN, KJ, or TJ VEHICLES: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin #9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC s. If the PCM becomes locked during reprogramming because the ABS CAB module connnector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Whenever a controller is programmed, the software in the DRBIII ; must be programmed with the latest revision level available. If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII. To satisfy this Repair Procedure the AN or KJ PCM, or the TJ TCM (EATX), require reprogramming (no other modules). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII memory. To clear the memory from the MAIN MENU power up the DRBIII and then: 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 DRB III reboots to the MAIN MENU, proceed to (STEP #2). 2. With the ignition switch in the RUN position, determine the original part number of the PCM or TCM (TJ) currently in the vehicle. Using the DRBIII select: a. DRBIII Standalone b Diagnostics c. All (Except Below) d. Engine Form TSB-003 Rev. 1.07

4 REV. A -4- e. Module Display f. Record the PCM part # on the repair order for later reference. 3. Connect the DRBIII to TechCONNECT. Open TechTOOLS and verify that the DRBIII Status: Connected message is in the upper right corner of the TechTOOLS screen. 4. Enter the PCM part # or the TCM part # recorded in (STEP #2) in the Parts Criteria area and select Show Updates. TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the DRBIII radio button which is next to the Download/Update button. 7. Select the Download/Update button. 8. 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 #9). 9. Disconnect the DRBIII from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 13.5 volts. 11. Connect the DRBIII to the vehicle. 12. Download the flash from the DRBIII to the vehicle. Using the DRBIII select: a. Vehicle Flash b. Follow the directions on the DRBIII screen. When the flash process is complete, proceed to (STEP #13). Due to the PCM (AN / KJ) or TCM (TJ) programming procedure, a DTC may be set in other modules (TCM, 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. The following step is required by law. 13. Type the necessary information on the Authorized Modification Label p/n AB and attach near the VECI label (Figure 1). REPAIR PROCEDURE FOR HB VEHICLES : REPAIR PROCEDURE USING THE INTERNET TO RETRIEVE THE FLASH FILE: The StarSCAN must be at version 4.06 or higher before this procedure can be performed.

5 REV. A FIGURE 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 The StarSCAN diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN for your dealership s network. For instruction on setting up your StarSCAN for the dealer s network; refer to the StarSCAN Quick Start Networking Guide available on the website under the download center. Make sure the StarSCAN is configured to the dealership s network before proceeding. If this flash process is interrupted/aborted, the flash should be restarted. 1. If the PCM is not operational, proceed to (STEP #3). If the PCM is operational, proceed to next step. 2. Retrieve the old PCM part number. Using the StarSCAN at the Home screen: b. Touch the screen to highlight the PCM in the list of modules. c. Record the Part Number, displayed on the ECU Overview screen, for later reference. 3. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 4. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer s network drop. 5. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle (optional). 6. Power ON the StarSCAN. Form TSB-003 Rev. 1.07

6 REV. A Download the flash file from the internet to the StarSCAN. Using the StarSCAN at the Home screen: a. Select Flash Download b. Select Use connected vehicle (StarSCAN must be connected to the vehicle) or Enter information manually (connection to the vehicle is not necessary). Press the Next button and follow the on screen instructions. c. Select the appropriate calibration. d. Select Download to Scantool. e. Select Close after the download is complete. 8. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle (if not already connected). 9. Open the hood, install a battery charger and verify the battery state is above 13.5 volts. 10. Download the file from StarSCAN to the vehicle. Using StarSCAN at the Home screen: b. Browse the list of controllers using the scroll arrows. Highlight the PCM. c. Select More Options d. Select ECU Flash e. Highlight the appropriate PCM Calibration from the list. f. Select Update Controller g. When update is completed, select OK 11. Program the PCM to the Wireless Control Module (WCM). Using the StarSCAN at the Home screen: b. Scroll through the list of controllers and highlight the WCM. c. Select Misc. Function. d. Highlight PCM Replaced. e. Select Start f. Follow the on screen instructions. Select Next after each step. Select Finish after completing the last step. 12. Program the PCM mileage. Using the StarSCAN at the Home screen: b. Scroll through the list of controllers and highlight the PCM. c. Select Misc. Function. d. Highlight Check PCM Odometer. e. Select Start f. Follow the on screen instructions. Select Next after each step. Select Finish after completing the last step.

7 REV. A 13. If the vehicle is equipped with a 3.7L or 4.7L engine, proceed to (STEP #14). Using the StarSCAN at the Home screen: b. Scroll through the list of controllers and highlight the PCM. c. Select Misc. Function. d. Highlight Learn ETC. e. Select Start f. Follow the on screen instructions. Select Next after each step. Select Finish after completing the last step. Due to the PCM programming 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. Check all modules using ECU View from the Home screen, 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. The following step is required by law. 14. Type the necessary information on the Authorized Modification Label p/n AB and attach near the VECI label (Figure 4). REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: Before flashing this module, make sure the StarSCAN is operating at the latest level and this is the latest flash file available from the StarSCAN update CD. To determine the latest StarSCAN software version level available refer to website under the Latest News link. If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the StarSCAN tool. For detailed information on the operation of the StarSCAN tool, refer to the Quick Reference documentation provided in the StarSCAN documentation kit. In addition, more recent information may also be available at the website. Look under Training Aids and also under Download Center > Frequently Asked Questions for more help. 15. Retrieve the old PCM part number. Using the StarSCAN tool at the Home screen: b. Touch the screen to highlight the PCM in the list of modules. c. Record the Part Number, displayed on the ECU Overview screen, for later reference. 16. Insert the USB Key, into the USB port on the TechCONNECT or equivalent PC (Figure 2). Form TSB-003 Rev. 1.07

8 REV. A -8- FIGURE 2 - USB KEY AND TECHCONNECT PC 1 TechCONNECT PC 2 ACCESS DOOR (ON FRONT OF TechCONNECT PC) 3 USB KEY IN THE TechCONNECT PC USB PORT 17. Insert the StarSCAN Software Update CD Release 4.07 or higher into the TechCONNECT or equivalent PC. The StarSCAN Software Update CD will start automatically. a. Select Controller Flash. b. Follow the on screen instructions. 18. Select Enter part number. a. Follow the on screen instructions. Enter the Part Number recorded in (STEP #15) when prompted to do so. Follow the on screen instructions. Select Next after each step. Select Finish after completing the last step. b. Proceed to (STEP #19). 19. Using the mouse highlight the appropriate Calibration a. Select Save to USB b. Follow the on screen instructions. Select Next after each step. Select Finish after completing the last step. 20. With the StarSCAN tool powered OFF, connect the USB Key and Gender Changer to the StarSCAN tool USB port (Figure 3). 21. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 22. Connect the StarSCAN tool to the vehicle.

9 REV. A FIGURE 3 - USB KEY, GENDER CHANGER, AND StarSCAN TOOL 1 StarSCAN TOOL 2 GENDER CHANGER 3 USB KEY 23. Power ON the StarSCAN tool. 24. Download the file from the USB key to the StarSCAN tool. Using the StarSCAN tool at the Home screen: a. Select Flash Download b. Select Use USB device c. Follow the on screen instructions. Select Next after each step. Select Finish after completing the last step. d. At the Flash File List screen, highlight the appropriate PCM Calibration e. Select Download to Scantool f. When the download is complete, select Close 25. Download the file from the StarSCAN tool to the vehicle. Using the StarSCAN tool at the Home screen: b. Browse the list of controllers using the scroll arrows. Highlight the PCM. c. Select More Options d. Select ECU Flash e. Highlight the appropriate PCM Calibration from the list. Form TSB-003 Rev. 1.07

10 REV. A -10- f. Select Update Controller g. When update is completed, select OK Due to the PCM programming 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. Check all modules using ECU View from the Home screen, 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. The following step is required by law. 26. Type the necessary information on the Authorized Modification Label p/n AB and attach near the VECI label (Figure 4). FIGURE 4 - 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 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation Description No: Reprogram 42RLE Transmission Control Module (PCM or TCM) Amount 0.8 Hrs. FAILURE CODE: FM Flash Module

SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTC s) P0403, P0404, P0405, P0406

SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTC s) P0403, P0404, P0405, P0406 NUMBER: 18-010-04 GROUP: Vehicle Performance DATE: March 2, 2004 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced,