2021-2025 Stellantis D Clutch Repair TSB 21-039-24

Owners of various 2021-2025 Stellantis vehicles equipped with the Eight-Speed Auto 850RE Transmission (Sales Code DFT) may encounter a Malfunction Indicator Lamp (MIL) illumination accompanied by specific Diagnostic Trouble Codes (DTCs). This issue, detailed in Technical Service Bulletin (TSB) 21-039-24 REV. H, points to problems within the transmission's D clutch. If you are experiencing a Stellantis D clutch P0733-00 or related fault, this bulletin outlines the necessary repair.

This bulletin, issued on December 13, 2024, supersedes TSB 21-039-24 REV. G, dated November 02, 2024. It provides updated information and procedures for addressing the D clutch malfunction.

Symptoms

Customers will typically notice a Malfunction Indicator Lamp (MIL) illumination on their dashboard. This warning light will be accompanied by one or more specific Diagnostic Trouble Codes (DTCs) stored in the vehicle's computer system, indicating an issue with the transmission's gear ratios or clutch performance. If your vehicle displays a Stellantis D clutch P0733-00 or similar code, it's crucial to have it inspected.

Fault Codes / DTCs

The following Diagnostic Trouble Codes (DTCs) are associated with this D clutch issue:

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

Diagnosis / Trigger Conditions

Diagnosis for this issue is straightforward: if the customer reports the Malfunction Indicator Lamp (MIL) illumination and the vehicle's system has set one or more of the specific DTCs listed above, the D clutch repair procedure should be initiated. If these DTCs are not present, the bulletin does not apply.

Important Warnings and Owner Advisories

Several critical warnings and notes are provided within the TSB to ensure proper repair and prevent further damage:

• Transmission Control Module (TCM) 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."
• 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 the detailed service procedures available in DealerCONNECT/Service Library under: Service Info>08 - Electrical/8E - Electronic Control Modules/ Module, Transmission Control/ Module Programming."
• Transmission Fluid Note: "NOTE: It is normal for the transmission to have fine debris present in the oil pan and stuck to the magnets. Burnt oil and debris do not warrant a transmission replacement for D piston seal failure."
• Transmission Positioning: "NOTE: The transmission must be in a vertical position before the main stack is removed, so damage to the drums does not occur."
• 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."
• Seal Installation: "CAUTION! The seal must be installed flush with the case. Driving the seal deeper could damage the seal causing a leak."
• Locknut Staking: "CAUTION! The nut must be staked to prevent vibration from backing the nut out or loose."

Repair Procedure Summary

The repair for the Stellantis D clutch P0733-00 and related DTCs involves a comprehensive D clutch replacement within the Eight-Speed Auto 850RE Transmission. This is a multi-step process requiring specialized tools and careful attention to detail.

Disassembly Phase:

1. The procedure begins with the removal of the torque converter. This is followed by the output shaft seal, output shaft snap ring (for 4x4 vehicles), and the output shaft flange locknut staking (for 2WD vehicles).
2. Next, the transmission oil pan is removed, and if equipped, the Hydraulic Impulse Oil Storage (H.I.S) connector is disconnected, and the H.I.S accumulator is removed.
3. The valve body assembly is then accessed by removing its end retainer bolts, disconnecting the electrical harness, and removing the Output Speed Sensor (OSS).
4. Using a Guide Sleeve (10377), the electrical harness insulator is pulled out, and the valve body assembly bolts are removed in a specific sequence.
5. Internal components such as the fluid port, fluid transfer tube, and input shaft O-ring are removed.
6. The oil pump housing bolts are removed and discarded, and the oil pump housing is carefully pried away from the case.
7. Further disassembly involves removing the B clutch spring damper, the park pawl lock rod, and the input/output shaft and P4 annulus drum assembly.
8. The input/output shaft and P4 annulus drum assembly are placed on a press fixture (8925-3) to facilitate the removal of the B clutch pack.
9. The P1 annulus/B clutch hub assembly, thrust bearing, holding plate, and various rings and snap rings are then removed.
10. The P1 planetary carrier, input shaft with P2 planetary carrier, P2 annulus/P3 sun gear, and finally, the D clutch drum are removed from the P4 annulus drum. The P4 planetary carrier/output shaft lock ring is also removed and discarded, to be replaced with a new one.

Reassembly Phase (D Clutch Replacement and Component Installation):

1. The new P4 planetary carrier/output shaft assembly is installed into the P4 annulus drum, along with a new lock ring, which is then staked.
2. The new D clutch drum is installed into the P4 annulus drum.
3. The P2 annulus/P3 sun gear, thrust bearing, and input shaft with P2 planetary carrier are reinstalled.
4. The snap ring, thrust bearing, holding plate, and selectable shim are installed onto the P1 planetary carrier and P1 annulus/B clutch hub.
5. The P1 annulus/B clutch hub assembly is installed onto the P4 annulus drum.
6. The B clutch discs and plates are installed, ensuring the transmission is vertical to prevent damage.
7. The input/output shaft and P4 annulus drum assembly are installed back into the transmission case.
8. The park pawl lock rod and B clutch damper spring are reinstalled.
9. The oil pump housing assembly is carefully positioned, and a new input shaft O-ring is installed.
10. New oil pump cover retaining bolts are installed and tightened in a specific sequence and torque.
11. The MPR lever is temporarily installed to release tension on the shift fork, then removed after the shift fork is aligned.
12. New fluid transfer tube O-rings and the fluid transfer tube are installed.
13. The valve body assembly is reinstalled using alignment pins, ensuring the shift fork lines up properly.
14. The electrical harness guide sleeve is installed using Guide Sleeve 10377, and the electrical connector lock is latched.
15. The valve body assembly end bolt is installed and tightened.
16. The OSS is installed, taking care to position its guide pin correctly.
17. If equipped, the H.I.S and its bolts are installed.
18. The OSS bolt is tightened, and the H.I.S wire harness connector is connected.
19. The MPR lever is returned to its original position, and its nut is installed and tightened.
20. The transmission oil pan and gasket are positioned, and the 13 transmission oil pan bolts are installed and tightened.
21. A new output shaft seal is positioned, and for 4x4 vehicles, installed using Seal Installer 9677.
22. For 4x4 vehicles, the extension housing and its bolts are installed.
23. For 2WD vehicles, the old output flange seal is discarded and replaced with a new one, and the output shaft flange is installed with a new nut and washer, which must be staked.
24. The torque converter is installed.
25. For WL 4x4 vehicles, the O-ring/seal is installed to the output shaft.

Post-Repair Steps: Before installing the transmission back into the vehicle, it must be pre-filled with the unique transmission fluid. After installation, a wiTECH Quick Learn Procedure must be completed, and any remaining DTCs must be cleared.

Required Tools or Parts

To perform this repair, specific tools and parts are necessary:

Special Tools:

• Guide Sleeve: 10377
• Press Fixture: 8925-3
• Bearing/Gear: 1130
• Rings, Support: 10378
• Installer, Seal: 9677

Spare Parts (Output Shaft Kits and Fluid):

• 68676890AB: Shaft Kit, Output (D Clutch Repair Kit for 4x4 JL, JT, WD, WK)
• 68676891AB: Shaft Kit, Output (D Clutch Repair Kit for 4x4 WL)
• 68676887AB: Shaft Kit, Output (D Clutch Repair Kit for 4x4 DS, DT, DX, WS)
• 68239499AD: Shaft Kit, Output (D Clutch Repair Kit for AWD LA, LD, LX)
• 68676892AB: Shaft Kit, Output (D Clutch Repair Kit for RWD LA, LD, LX)
• 68676894AB: Shaft Kit, Output (D Clutch Repair Kit for RWD WD, WK, WL)
• 68676893AB: Shaft Kit, Output (D Clutch Repair Kit for RWD DS, DT, DX, WS)
• 68218925AB: Automatic Transmission Fluid

Owner Action

If your 2021-2025 Stellantis vehicle displays a Malfunction Indicator Lamp (MIL) illumination and you suspect a transmission issue, particularly if you've encountered a Stellantis D clutch P0733-00 or related fault code, it is recommended to contact your authorized Stellantis dealer. They can perform a diagnostic scan to confirm the presence of the specified DTCs and carry out the necessary D clutch replacement as outlined in TSB 21-039-24 REV. H.

Warranty Information

This repair is reimbursable within the provisions of the warranty. Owners should consult their dealer for specific warranty coverage details.

NHTSA ID: 11011921