Major Transmission Repair

[cropi]

2003 Dodge Diesel 2500

5.9













Problem was: I put truck in reverse but did not engage, after releasing gas it went into reverse, hard. No noise, no other problems. Knew a problem was starting or I thought. Next day went into reverse fine, put into gear to drive and
truck crawled out of driveway but gas had to be applied as I was pulling a extreme load. Took to shop at it was taking off in 2nd gear. SHOP Estimate: When they pulled the transmission pan, it was full of milky brown fluid, not bad as of metal shavings. very little on magnet. Had to replace all internal transmission parts, but did upgrade to Dodge recommendations. They also flushed out engine and replace a engine seal back of the engine plate that was leaking. Radiator had transmission fluid in it so they flushed the radiator as well and changed a pump that (radiator fluid goes thru to cool transmission) Torque Converter pump? Trans convertor pump? (located drivers side under the engine. Can see it looking under drivers fender well, connects to all metal lines. Extremely expensive pump, over 1600, 6/8 hrs to change. WOW..... Dealer stated they had never seen this pump having to be replaced????? Transmission works well now. Other then NO One can tell me how it got this bad, only thing they state is it looks as the truck was submerged in water.??? But I have a loud pop and hissing sound when first start. Also a slight ticking other then the diesel sound. My Question: Has anyone been thru anything like this, any thoughts or help. At this point don't know what other harm has been done. Thanks

 

[Killer223]

you got taken to the cleaners.
there is no pump for the trans, the water pump at front of engine maybe, but it's not hard to replace nor is it costly part. the part that failed was the trans heat exchanger, it's on the PASSENGER side, under the exhaust manifold. they are known to leak and kill the trans. the rebuild is ok, hope they put upgraded electronics in it.
i'd find a new shop and have the valves adjusted and tell them nothing of the recent work.
Loud pop and hissing might be exhaust leak, or intake boot leak. check into those.

 

[sag2]

Actually it is on the drivers side. There was also a recall on them but not sure of the years. It is very easy to replace when the transmission is out, hard with it installed. List price on the cooler 68253200AA is $920.

Looked up the recall.
2003-2004 (DR) Dodge Ram Pick-Up Trucks
NOTE: This notification applies only to the above vehicles equipped with a 5.9L
Cummins diesel engine (Sales Code ETC or ETH) and an automatic transmission
(Sales Code DG8 or DGP) built through November 24, 2003 (MDH 112407).

 

[Killer223]

Yes!! My bad! I was remembering the older school ones.. My mistake...

 

[diesel_driver]

Actually it is on the drivers side. There was also a recall on them but not sure of the years. It is very easy to replace when the transmission is out, hard with it installed. List price on the cooler 68253200AA is $920.

Looked up the recall.
2003-2004 (DR) Dodge Ram Pick-Up Trucks
NOTE: This notification applies only to the above vehicles equipped with a 5.9L
Cummins diesel engine (Sales Code ETC or ETH) and an automatic transmission
(Sales Code DG8 or DGP) built through November 24, 2003 (MDH 112407).

Interesting. I never received the recall notice for the heat exchanger, and I ordered my truck in, I believe, August 2003. It was delivered to me the first part of October 2003. I recently checked with my local dealer about the airbag recall status, and asked if any other recalls were pending, and was told "no."

 

[RVTRKN]

When they pulled the transmission pan, it was full of milky brown fluid, not bad as of metal shavings. very little on magnet.

AAMCO did that to me when I took my 94 2500HD gasser auto in for service in 2002. Pulled the pan and claimed oil was burn't and transmission needed rebuilding. I told them no, so they put same oil back in and gave me truck back. I took it to a reputable transmission repair shop I found after the fact, and they said it was ok, serviced it and explained the minor problem (longer time for shifts from 2nd to 3rd) was due to a "O" ring stiffening and not seating correctly. They said I could drive it and if it got worse, then a rebuild would be warranted. I found an additive called "Trans X" and followed directions and it went away. The "O" ring softened up and it seated correctly. I see that truck all the time in my neighborhood, and even though it looks like crap now (work truck) it's still running the same trans.

I know my issue was not the same as yours, but a second opinion sometimes can save lots of dollars. Hope it all works out for you.

 

[cerberusiam]

The biggest harm done is to the trans when the TC cooler leaks coolant into the trans fluid. If the trans has been rebuilt, TC cooler replaced, front cooler replaced and all lines flushed you are good unless it breaks again. Might have to flush the engine again to get all the trans fluid out of it if it leaked that way, some times they don't.

Part of the problem on the early trucks was the cooler output line from the trans to the TC cooler was solid, it had no vibration coupler in it. All the later trucks has a rubber line in it to stop the problems, hopefully they replaced the line and it has a rubber section in it.

The older TC coolers were much better because they had lead in the solder. Along about 2006 or so EPA mandated removal of lead and the quality MTBF went down. Dealer is in business to make money so they sold you OE parts when what most of us do when they go bad is just leave the TC cooler off and add a high efficiency thermo controlled cooler with fan under the box.

In answer to your question, it happens, just not very frequently. The TC coolers are pretty robust and a lot of failures are due to wrench monkeys NOT using a backup wrench on the lines when removing or replacing them. The older ones on the passenger were almost indestructible but no room with the way the turbo mounts in a 3rd gen to use them.

 

[sag2]

I forgot to mention that the recall also includes a revised line as Cerb mentioned.
For the OP, I would contact Chrysler at 1800 992-1997 with your VIN and ask them why your truck was not involved in the recall (if it does fall within the dates). If it does fall within the dates I would ask them to refund the cooler and labor. They will not pay for the trans damage as the recall was for external leaks that could cause a fire. I would not get too specific about the other damage, just concentrate on getting the refund for the cooler. Anything else you get would be a bonus.

 

[BigPapa]

I forgot to mention that the recall also includes a revised line as Cerb mentioned.
For the OP, I would contact Chrysler at 1800 992-1997 with your VIN and ask them why your truck was not involved in the recall (if it does fall within the dates). If it does fall within the dates I would ask them to refund the cooler and labor. They will not pay for the trans damage as the recall was for external leaks that could cause a fire. I would not get too specific about the other damage, just concentrate on getting the refund for the cooler. Anything else you get would be a bonus.

Good advice from someone who knows right there.