2020-2023 Stellantis D Clutch Transmission Repair TSB

Stellantis has issued Technical Service Bulletin (TSB) 21-039-24 REV. G to address a specific transmission concern affecting various 2020-2023 models equipped with the Eight-Speed Auto 850RE Transmission (Sales Code DFT). This bulletin, dated November 2, 2024, supersedes TSB 21-039-24 REV. E, issued on October 10, 2024. Revisions in this update include new market applicability, an updated Spare Parts table, the addition of a special tool, and revised torque values and sequences in the repair procedure.

The TSB focuses on resolving issues related to the D clutch within the transmission, which can lead to a Malfunction Indicator Lamp (MIL) illumination and specific diagnostic trouble codes. Owners of affected vehicles, including the Jeep Wrangler, should be aware of these symptoms and the recommended repair.

Symptoms

Owners may notice a "Malfunction Indicator Lamp (MIL) illumination" on the dashboard. This warning light indicates a problem that requires attention. In conjunction with the MIL, the vehicle will set one or more of the following Diagnostic Trouble Codes (DTCs):

• 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 issues within the transmission's D clutch system, affecting gear engagement and ratio integrity.

Diagnosis and Trigger Conditions

Diagnosis for this issue is straightforward: if a customer reports the MIL is illuminated and a scan tool confirms the presence of DTCs P0733-00, P1DA8-00, or P1D92-00, the vehicle is subject to this bulletin. If these specific DTCs are not present, the bulletin does not apply.

Important Warnings and Notes for Technicians

Several critical warnings and notes are provided in TSB 21-039-24 REV. G to ensure a successful repair and prevent further damage:

• Clutch Pack Tagging: All clutch pack assemblies must be tagged as they are removed to ensure correct reassembly identification.
• Transmission Fluid Debris: It is normal to find fine debris and magnets in the oil pan. Burnt oil and debris alone do not indicate a need for transmission replacement due to D piston seal failure.
• Transmission Vertical Position: When removing or installing the main stack of components, the transmission must be kept in a vertical position to prevent damage to the drums.
• Electrostatic Discharge (ESD) Sensitivity: The Transmission Control Module (TCM) or Transmission Control Module Assembly (TCMA) is highly sensitive to ESD. Technicians must use a ground strap and follow ESD guidelines to prevent damage to these components.
• TCM Adaptation Procedure: After any clutch or seal replacement, or if the transmission is replaced, a TCM Adaptation Procedure is mandatory. Refer to DealerCONNECT/Service Library under "Service Info>08 - Electrical/8E - Electronic Control Modules/Module, Transmission Control/Module Programming" for detailed steps.
• Unique Transmission Fluid: This transmission requires a unique fluid that is NOT compatible with ATF+4 or any other current FCA US LLC transmission fluid. Always refer to the FLUIDS, LUBRICANTS AND GENUINE PARTS section for specifics.
• Seal Installation: When installing the transmission oil pan seal, it must be flush with the case. Driving the seal deeper can damage it and cause a leak.
• Output Shaft Flange Nut Staking (2WD): For 2WD vehicles, the output shaft flange nut must be staked to prevent it from backing out due to vibration.
• Output Speed Sensor (OSS) Alignment: Care must be taken to correctly align the OSS guide pin during installation to avoid sensor damage.

Repair Procedure Summary

The repair outlined in TSB 21-039-24 REV. G involves the replacement of the D clutch. This is a comprehensive procedure requiring significant disassembly and reassembly of the transmission. The steps include:

1. Initial Disassembly: The torque converter is removed. For 4WD vehicles, the transmission housing extension and output shaft snap ring are removed. For 2WD vehicles, the output shaft flange locknut staking is removed. The transmission oil pan, gasket, Hydraulic Impulse Oil Storage (H.I.S.) (if equipped), valve body assembly, Output Speed Sensor (OSS), fluid port, and fluid transfer tube O-rings are all carefully removed.
2. Clutch Pack Access: The input shaft O-ring and oil pump housing bolts are removed and discarded. The oil pump housing is then pried away and removed. The B clutch spring damper, input/output shaft, and P4 annulus drum assembly are extracted.
3. D Clutch Component Removal: The input/output shaft and P4 annulus drum assembly are positioned on a Press Fixture (8925-3). The B clutch pack, P1 annulus/B clutch hub assembly, thrust bearing, holding plate, P1 planetary carrier, input shaft with P2 planetary carrier, P2 annulus/P3 sun gear, and finally the D clutch drum are all systematically removed.
4. Reassembly and New Part Installation: A new P4 planetary carrier/output shaft lock ring is installed and staked. The D clutch drum, P2 annulus/P3 sun gear, thrust bearing, washer, and input shaft with P2 planetary carrier are reinstalled. The snap ring, thrust bearing, holding plate, selectable shim, and P1 annulus/B clutch hub assembly are installed. The B clutch discs and plates are installed, followed by the snap ring.
5. Transmission Case Reassembly: The input/output shaft and P4 annulus drum assembly are installed into the case. The park pawl lock rod and guide plate are reinstalled, with bolts tightened to 10 N-m (89 In. Lbs.). The B clutch damper spring is installed. The oil pump housing assembly is positioned, and a new input shaft O-ring is installed, ensuring the oil pump is firmly pressed into place before drawing it in with new bolts. The new oil pump cover retaining bolts are tightened in a specific three-stage sequence: pre-tighten bolts 1, 7, and 9 to 6 N·m (53 in. lb.), then tighten all bolts clockwise from 1 to 10 N-m (89 in. lb.), and finally tighten all bolts clockwise from 1 an additional 90°.
6. Final Assembly: The MPR lever is temporarily installed to release tension on the shift fork, then removed. New fluid transfer tube O-rings and the fluid transfer tube are installed. The valve body assembly is reinstalled using alignment pins, and its bolts are tightened to 8 N-m (71 In. Lbs.). The electrical harness guide sleeve (using Guide Sleeve 10377) and electrical connector lock are reinstalled. The OSS is carefully installed, with its bolt tightened to 8 N-m (71 In. Lbs.). If equipped, the H.I.S. and its bolts are installed and tightened to 8 N-m (71 In. Lbs.), and its wire harness connector is reconnected. The MPR lever nut is installed and tightened to 12 N-m (9 Ft. Lbs.).
7. Oil Pan and Seals: The transmission oil pan and gasket are positioned, and the 13 oil pan bolts are tightened to 10 N-m (89 In. Lbs.). A new output shaft seal is positioned and installed using Seal Installer 9677. For 4X4 vehicles, the extension housing is positioned and its bolts tightened to 27 N-m (20 Ft. Lbs.). 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, ensuring the nut is staked.
8. Post-Installation: The torque converter is installed. The transmission is pre-filled, installed into the vehicle, and a wiTECH diagnostic tool is used to complete the Quick Learn Procedure and clear any remaining DTCs.

Required Tools and Parts

Special Tools:

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

Replacement Parts:

• D Clutch Repair Kits (Shaft Kit, Output):
  • 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, WL)
  • 68676893AB (RWD DS, DT, DX, WS)
• Automatic Transmission Fluid: 68218925AB (10 units, as required)

Warranty Information

This repair is reimbursable within the provisions of the warranty. The bulletin specifies various labor operation numbers for the D clutch inspection and replacement, ranging from 21-00-64-90 to 21-00-64-95, with labor times between 5.4 and 9.7 hours depending on the vehicle model. An additional labor operation, 21-00-00-51, is allocated for the Adaptation Procedure, with a labor time of 1.0 hours. The failure code for this service action is ZZ.

What Owners Should Know

If you own a 2020-2023 Stellantis vehicle equipped with the Eight-Speed Auto 850RE Transmission and experience a "Malfunction Indicator Lamp (MIL) illumination" or suspect transmission issues, it is crucial to have your vehicle diagnosed by a qualified technician. They can confirm the presence of the specific DTCs (P0733-00, P1DA8-00, P1D92-00) and perform the necessary D clutch repair. This repair is complex and requires specialized tools and knowledge, so it should only be performed by trained professionals.

This bulletin is for technical information only and does not authorize repairs outside of warranty provisions.

NHTSA ID: Z21 FSAR-TSB-4744