2021-2023 Stellantis D Clutch Repair TSB 21-039-24

Stellantis has released Technical Service Bulletin (TSB) 21-039-24 REV. B, dated August 7, 2024, to address issues with the D clutch in various 2021-2023 models equipped with the Eight-Speed Auto 850RE Transmission (Sales Code DFT). This bulletin supersedes TSB 21-039-24 REV. A, issued on June 14, 2024, and includes an updated repair procedure for the Stellantis D clutch repair.

This TSB is applicable to a wide range of vehicles, including the 2022 Wagoneer / Grand Wagoneer, 2020-2023 Dodge Durango, 2020-2023 Dodge Charger, 2020-2023 RAM 1500 Pickup, 2021-2023 RAM 1500 Classic, 2021-2023 RAM Truck (Mexico), 2020-2023 Jeep Grand Cherokee, 2021-2023 Jeep Grand Cherokee / Grand Cherokee L, 2020-2023 Jeep Gladiator, 2020-2023 Jeep Wrangler, and 2020-2023 Chrysler 300. The primary solution for this issue is a D clutch repair.

Symptoms

Owners of affected vehicles may notice a "Malfunction Indicator Lamp (MIL) illumination" on the dashboard. This warning light indicates a problem with the vehicle's transmission system. The underlying issue is related to the D clutch, which can lead to incorrect gear ratios.

Fault Codes / DTCs

When the MIL illuminates, technicians will typically find one or more of the following Diagnostic Trouble Codes (DTCs) stored in the vehicle's system:

Code	Description
P0733-00	Gear 3 Shift Incorrect Ratio
P1DA8-00	Incorrect Gear Ratio Clutch A B or D Defective
P1D92-00	Incorrect Gear Ratio - Clutch 4 Defective

These codes specifically point to problems with the transmission's ability to engage or maintain the correct gear, particularly involving the D clutch and other related clutch components.

Important Warnings

Several critical warnings are highlighted in TSB 21-039-24 REV. B to ensure proper repair and prevent further damage:

• Transmission Control Module (TCM) / Transmission Control Module Assembly (TCMA) Sensitivity: "CAUTION!! The Transmission Control Module (TCM), or Transmission Control Module Assembly (TCMA) is extremely sensitive to Electrostatic Discharge (ESD). Always use a ground strap and follow the ESD guidelines in ELECTROSTATIC DISCHARGE SENSITIVE DEVICES. Failure to follow these instructions may result in damage to the TCM/TCMA."
• Unique Transmission Fluid: "CAUTION!! A unique transmission fluid has been developed for this transmission. This fluid is NOT compatible with ATF+4 or any other current FCA US LLC transmission fluid. For specifics about this unique fluid see FLUIDS, LUBRICANTS AND GENUINE PARTS."
• TCM Adaptation Procedure: "NOTE: If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the TCM Adaptation Procedure (Refer to 08 - Electrical/8E - Electronic Control Modules/Module, Transmission Control/ Module Programming)."
• Transmission Vertical Position: "NOTE: The transmission must be in a vertical position before the main stack is removed, so damage to the drums do not occur." This note is repeated multiple times throughout the repair procedure.
• Snap Ring Removal: "NOTE: Pry the snap ring from the opposite side of the snap ring openings to release." and "NOTE: When the snap ring is removed the internal clutch drum may drop slightly."
• Prying Protection: "NOTE: The are three pieces intended to be used in multiple locations around the drum to prevent damage from prying." (repeated)
• Manual Park Release (MPR) Lever: "NOTE: The Manual Park Release lever can be reversed to release tension and ease the installation of the valve body assembly."
• Shift Fork Alignment: "NOTE: Make sure the shift fork lines up properly."
• Guide Pin Removal: "NOTE: After several bolts have been hand tightened, remove the guide pins."
• Seal Installation: "CAUTION!! The seal must be installed flush with the case. Driving the seal deeper could damage the seal causing a leak."
• WL 4x4 Specific O-ring: "NOTE: **For WL 4x4 Only. Install green o-ring to output shaft Fig. 56."

Diagnosis

If a customer reports the illuminated "Malfunction Indicator Lamp (MIL) illumination" and any of the DTCs P0733-00, P1DA8-00, or P1D92-00 are present, the Stellantis D clutch repair procedure outlined in TSB 21-039-24 REV. B should be followed. The initial diagnostic step involves performing a pressure check on the D clutch circuit using the dealer connect procedure. This helps confirm the D clutch failure before proceeding with the physical repair.

Repair Procedure Summary

The repair detailed in TSB 21-039-24 REV. B primarily involves replacing the D clutch within the Eight-Speed Auto 850RE Transmission. The process is extensive and requires specialized tools and expertise. Here's a high-level overview:

1. Initial Checks: Verify the presence of the specified DTCs and perform a D clutch circuit pressure check.
2. Transmission Removal: The transmission must be removed from the vehicle. This includes detaching the torque converter and, for 4WD models, the extension housing.
3. Disassembly: Key components are removed in a specific sequence: the transmission output shaft seal, output shaft snap ring, and transmission oil pan. The Hydraulic Impulse Oil Storage (H.I.S) connector is disconnected, followed by the removal of the valve body assembly, Output Speed Sensor (OSS), and electrical harness insulator. The fluid port, input shaft O-ring, and oil pump housing are also removed.
4. Clutch Pack Access: The B clutch spring damper, park pawl lock rod, input/output shaft, and P4 annulus drum assembly are carefully removed. Further disassembly involves removing the P1 planetary carrier, input shaft with P2 planetary carrier, and the P2 annulus/P3 sun gear.
5. D Clutch Replacement: The D clutch drum is then removed from the P4 annulus drum. A new P4 planetary carrier/output shaft lock ring is installed, followed by the installation of the new D clutch drum into the P4 annulus drum.
6. Reassembly: The transmission is reassembled in the reverse order of disassembly. This includes installing new seals and O-rings as required, ensuring proper alignment of components like the shift fork, and correctly positioning the Output Speed Sensor.
7. Final Steps: After the transmission is reinstalled in the vehicle, it must be pre-filled with the correct, unique transmission fluid. Finally, a Quick Learn Procedure must be completed using the wiTECH diagnostic tool, and any stored DTCs must be cleared.

Required Tools or Parts

Performing this Stellantis D clutch repair requires specific tools and parts to ensure the repair is done correctly:

• Special Tools:
  • Guide Sleeve (Ref. No. 10377)
  • Press Fixture (Ref. No. 8925-3)
  • Bearing/Gear (Ref. No. 1130)
  • Rings, Support (Ref. No. 10378)
• D Clutch Repair Kits (Part Numbers vary by drive type and model):
  • 68676890AB (4x4 JL,JT,WD,WK)
  • 68676891AB (4x4 WL)
  • 68676887AB (4x4 DS,DT,DX,WS)
  • 68239499AD (AWD LA,LD,LX)
  • 68676892AB (RWD LA,LD,LX)
  • 68676894AB (RWD WD,WK)
  • 68676893AB (RWD DS,DT,DX,WS)
• Automatic Transmission Fluid: Part No. 68218925AB

Owner Action

If your 2021-2023 Stellantis vehicle, including models like the Jeep Wrangler, Dodge Durango, or RAM 1500, displays a "Malfunction Indicator Lamp (MIL) illumination" or stores any of the DTCs P0733-00, P1DA8-00, or P1D92-00, it indicates a potential D clutch issue. It is crucial to contact your authorized Stellantis dealer to have the vehicle diagnosed and the Technical Service Bulletin 21-039-24 REV. B repair performed. This Stellantis D clutch repair is covered under warranty provisions.

NHTSA ID: 11006254