Engine/Transmission (1994 - 1998) Torque Converter woes in '95 Ram 2500 TCD

[StevenBryant]

Hello to all! I'm new to TDR, just subscribed a hair over a week ago. The Dodge Ram with Cummins has been my dream truck for 9+ years, and my dream finally came true 3 weeks ago. I bought a '95 Dodge Ram 2500 CTD with ext cab, 4X4, AT, Power pretty much every thing, K&N, has 72,000 miles on it. I love this truck!



Now, on to the problem. The last couple weeks, I've noticed a problem with the TC. I initially thought it was the transmission being squirrelly, and popping in and out of over drive. Between 50 and 65 miles per hour, it would feel like it shifted down, kicking the RPM up by 250, and then almost immediately shift back up, sometimes doing this multiple times. Now that I've been driving the truck a bit longer, and can tell the difference between overdrive kicking in, and the TC engaging, I'm fairly certain it's the TC kicking in and out. The problem is fairly sporadic, but after searching this site and finding a few posts that seemed to deal with the problem, I tried a few fixes and started paying more attention to when the problem occurred. Here's the low-down.

Fixes:

I've split the 3 wires for the TPS from the first bundle it's a part of. My questions is, do I need to remove these wires from every bundle they're in? In other words, do I need to split them out of every loom they're in from starting point to termination? That's what I'd try to do if it was a network cable, but wasn't sure about this one...

I've unplugged the TPS and sprayed the plug and socket down with contact cleaner, and tried a little on the throttle linkage as well.

These two fixes seemed to take care of the problem... until the day before yesterday. Every time it's happened, I've checked every gauge I have to see what the commonalities are, so here goes.

Conditions:

It only seems to happen (with one exception) when the transmission temp hasn't reached 135* or so yet. Until yesterday, it had never happened when I had the overdrive lockout on, but yesterday, it did it once. It only seems to happen if I'm going up a slight incline or slight decline with the gas pedal barely pressed (1-2 inches of travel). I've never noticed it when using cruise control. I got to thinking of the times it's happened, and it seems like it's worst when it's raining, or the road is still wet from it raining that day. Engine temp (from in dash gauge, the pyrometer hasn't arrived yet) doesn't seem to have any effect on problem.



Sorry this post is so long. Any suggestions? If anyone needs to talk directly to me for more info, I'd be happy to give you my phone number. Any help would be greatly appreciated!

 

[Dave Remillard]

Have you checked the TPS voltage? I have a 95 also, and near as I can tell that is the year that displays this problem the most. If you can get 1. 2V or a bit more at idle, that should do it. I recently bought a DTT TC Saver for this problem. I have not installed it yet to see how well it works. It's an earlier version that I picked up on e-bay for about 20% of retail. From what I've read, they work very well. Might be worth a call also to Bill K. at DTT. Great guy and willing to help on transmission related issues.

 

[Extreme1]

It's the TPS. Remove the switch from the truck and spray cleaner into the back side (there is a groove around the pivot that does on the end of the throttle shaft). Rinse it out really good (I've read posts about members seeing a lot of black crud coming out of it). Then twist it back and forth many, many times.



Let it dry out (better yet blow it out with compressed air) before using it.

 

[rrausch]

Welcome to the TDR Steve! I Love my '95 too! I got mine with 57,000 on the odo 3 years ago and since then have put another 70,000 on it with no problems at all... except the one you mention! I just spray my TPS with Electrical Contact Cleaner every once in a while... it is due again.



When I had 107,000 miles on the truck, I solved my transmission problems by getting a Performance Trans. My TPS still acts up occasionally, but I got the ATS Stage IV Performance Trans, and I also got the ATS digital box (The TripleLok Commander) so I can set lock-up at any road speed I want, from about 18 M. P. H. up to 55 or so... so if the TPS begins to act up, I just lock the TC with the TripleLok Commander! For some reason after driving a bit with the TripleLok Commander locking the TC, my TPS behaves itself again. I have no idea why this works for me, there is no reason to it, but it does! A better solution is of course to spray it clean, which I have been putting off because I ran out of Electrical Contact Cleaner, and have neglected to get more.

 

[PKemp]

Like he says its more than likely the TPS. Yes, completely separate the wires from the looms and put them in their own plastic loom. Then check the voltage (1. 2 volts seems to work the best) If you can't get that voltage loosen and readjust the frame the TPS mounts to rather than rounding out the holes on the TPS (you can get a wider range of voltage that way).

But... ... ... . Whats the fluid look like? Smell? When was the filter changed last? Are the contacts on the temperature switch good and clean? Has the throttle cable recall been done on your truck. Have the bands been adjusted in the last 30k?

I had the identical problems you describe and after doing all this it still wasn't fixed and slowly got worse. Turned out to be a lip seal leaking in the transmission.

Start putting your $$$ in a box and when you can, get a heavy duty TC and transmission and be done with it. Check the "transmission" posts on the site, there are many good ones (ATS, DTT, Sun Coast, etc, etc, etc).

Good luck and please let us know how it goes, this is an annoying, time consuming and recurring problem on the 95's to 97's.



--- Pat

 

[DKayser]

TPS

RRausch! My 95 acted the same, put the mystery switch in-problem gone. Used it a lot. Serviced trans,forgot switch on test drive, no more problem. This sounds like yours. I thought I solved problem by trans service, apparently not. I hate to think it will return, but I guess it ain`t a biggy now. Huh, learned something tonite. DK.

 

[rrausch]

Yup! Before I went with ATS, I had a mystery switch also, and I used it in the same way, and it always solved the problem too! I can't see why, but it did.

 

[Jim Fulmer]

Steven You don't need a $4000. 00 transmission to fix this problem.



Jim

 

[inarush76]

noise filter

clean and adjust TPS, reset(disconnect batteries for several minutes,key on, engine off, press throttle to floor and release, turn key off), call DTT and talk to Bill (1-866-504-4002), order noise filter from DTT, this should cover most causes. HTH

James

 

[PKemp]

J. Fulmer is right, you don't NEED a $4000 transmission to fix this problem. The TPS clean and adjust and that noise filter are good bets. Check the other things I mentioned though, its just a good habit when you change the transmission fluid. I had a really bad run of luck with these trannys and went thru 3 of them before going heavy duty. I didnt have much help from the local dodge dealer either. They knew less than me (thats scarry). If it wasn't for these guys on here I'd have been done. Most of them have been there and done that. After trying all of their suggestions and help I did find out a lot more about my truck than I thought possible, so listen good, no use in trying to re-invent the wheel. Maybe Howard Durand will chime in too he's an ace on this stuff.

Let us know how it turns out.

 

[StevenBryant]

PKemp: Yesterday, a friend and I did the KDP fix and installed a new main seal. While we were at it, I disconnected the Trans temp sensor and the speed sensor and went to town with the contact cleaner. I made good and sure that the harnesses and pins down there were clean and sealed when plugged in. The transmission fluid is good, no burnt smell, still a pretty red. The recall fix has been done, and the transmission was serviced less than 20k ago.

All: I took the truck hunting today, hour and a half drive each way, so I have a better idea of precisely when the problem occurs. I know I posted it doesn't unless OD is engaged, but that's not true. I also noticed today that temp doesn't seem to have as much to do with it as I initially thought. Regardless of temp, regardless of uphill/downhill, OD, etc, if I'm going about the speed or faster where the TC should kick in, and the gas pedal isn't depressed more than 1/2-1 inch, the problem occurs. If I press the pedal more, it kicks back in. I have yet to see it happen, under any condition when I've got the pedal pressed more than an inch or so. I'm thoroughly convinced it's the TPS, and plan on checking voltage, seperating the wires from all the looms, and cleaning as completely as I can. I'll let you all know how it goes. BTW, where can I buy one of those noise filters? I use that sort of thing in my job, and was wondering if anything like that existed for this. .

Quick question: how hard is this on the TC? I can't imagine it's very good for it.

Thanks for all your replies and help!

 

[rrausch]

How hard it is on the TC Clutch depends on how much load the truck is pulling or carrying, and how much pedal you are giving it when it acts up. Personally, from observing this problem in my truck, I find it more annoying than serious, but it has never happened to me while I was towing or carrying a heavy load. Perhaps I have been lucky, but it has only happened to me while running empty. Don't know why.



Much more serious is the stock TC Clutch over-heating and degrading from slipping while locked. This generally happens while towing or carrying a heavy load up an incline, TC locked, but slipping.

 

[Howard Durand]

At the PCM, connect an electrolytic capacitor (about 400 microfarad/25 volts) between the TPS signal wire and the ground wire.

That should attenuate the noise.

 

[StevenBryant]

Hello to all! Well, Friday night, I took the TPS off and cleaned the heck out of it with contact cleaner. Not too terribly much crud came out, but some did. I noticed while I was working the contact back and forth with a screwdriver that it didn't want to go back to full off right away, but would after a bit. In other words, it would spring most of the way back to full rest, but not all the way immediately. I don't know if that has any bearing or not, but figured I'd mention it. I started to split the wires out of the rest of the looms they're in, but gave up when I got to the second junction where they twist all the way around the bundle. Anyway, I got out my multimeter and tested voltage with the help of my gracious wife, and discovered it was only putting out 8. 4v or so at idle. I know that's supposed to be within the "acceptable" range, but at the bottom of that range. Besides, from the replies here, I know 1. 2v is supposed to work better. I went to adjust the voltage the way the service manual says to, but discovered I didn't have the correct wrench. So, I decided to adjust the frame the TPS mounts to, but discovered I was unable to get to the bolts with the sockets and whatnot I had. *sigh* Well, I have a dremel, and I have bits for cutting plastic, so I used that to elongate the holes on the tps. That worked. I'm now getting 1. 1+v at idle, and 3. 8v or so at WOT. I've taken the truck for two test runs since then, and have been unable to recreate the problem. I'm going to wait to declare it fixed though until I have the chance to run it for longer periods and distances multiple times. (In other words, until I've driven back and forth to work for a couple weeks. )

I can't thank all of you enough for your help and advice. If I hadn't been able to talk to you through TDR, I would have ended up taking this to a dealership, which may or may not have been able to figure out the problem. I'll keep you all updated on how things turn out. Thanks again!

 

[StevenBryant]

Here's why you're supposed to proof-read! . 84v is what I was originally getting at idle, not 8. 4. Sorry!

 

[Dave Remillard]

Steven... To answer your question about where to get a noise filter. Howard offered one idea, however another would be to contact DTT and order one of theirs. More spendy than buying one at a electronics gismo store, but the one they offer is incapsulated and will resist the elements. Just another idea. It sounds like you may have it corrected, but believe me, IT WILL come back.

 

[StevenBryant]

Well, I've run it for over 700 miles now with no problems. I think the problem is fixed for now. Thank you very much guys!