Technical Service Bulletin (TSB)
Replace K1 Clutch / Input Shaft Assembly
REFERENCE:

TSB: 21-051-24
GROUP: 21 - Transmission and Transfer
Case

Date:

September 27, 2024 REVISION: 21-002-23 REV. B

VEHICLES
AFFECTED:

2019 - 2023 (DD) RAM 3500 Cab Chassis
2019 - 2023 (DP) RAM 4500/5500 Cab Chassis
2019 - 2023 (D2) RAM 3500 Pickup
This bulletin applies to vehicles built on or before December 01,
2022 (MDH 1201XX) equipped with a 6SPD Auto Aisin AS69RC HD
Transmission (Sales Code DF2) or a 6SPD Auto Aisin AS66RCHD
Trans (Sales Code DF3).
For 2019 - 2021 MY vehicles, this Technical Service Bulletin (TSB)
only applies to vehicles that have had a complete NEW transmission
replaced between 02/01/2022 and 12/18/2022.

MARKET APPLICABILITY:
NA

MEA

SA

IAP

EE

CH

CUSTOMER
SYMPTOM:

Customers must experience a Malfunction Indicator Lamp (MIL) illumination and the vehicle must
exhibit/set the following Diagnostic Trouble Code (DTC):
● P0731-00 - Gear 1 Shift Incorrect Ratio (This DTC will set during a key cycle and shifting into Drive).
Customers may also comment on the following:
● The transmission will not shift into or out of 1st - 4th gears. 5th and reverse gears are still available.

CAUSE:

**K1 clutch manufacturing issue that results in a loss of torque transfer for lower gears 1, 2, 3 and 4.**

This bulletin supersedes Technical Service Bulletin (TSB) 21-002-23 REV. B, date of issue August
19, 2023, which should be removed from your files. All revisions are highlighted with **asterisks**
and include an updated Cause, a new RSU number, an updated RSU statement, new and updated
LOPs and times, an updated Repair Summary, updated Spare Parts table, updated Diagnosis section
including a new note, and an updated Repair Procedure. Additionally a spare parts table was removed
and not highlighted with asterisks.
**This Technical Service Bulletin (TSB) has also been released as a Rapid Service Update (RSU)
24-137, date of issue September 27, 2024. All applicable RSU VINs have been loaded. To verify this
RSU service action is applicable to the vehicle, use VIP or perform a VIN search in DealerCONNECT/
Service Library. All repairs are reimbursable within the provisions of warranty.**
REPAIR SUMMARY:
**This bulletin involves replacing the K1 clutch and possibly the K1 input shaft drum sub-assembly. These
repairs are to be performed only if the vehicle is inoperable due to K1 clutch failure. **

J21 FSAR-TSB-4607

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CLAIMS DATA:

Labor Operation No:
**21-00-0A-91

Labor Description
K1 Clutch / Input Shaft
Assembly - Inspect and
Replace Sub-Assembly
(3 - Highly Skilled)

Skill Category
2 - Transmission and
Transfer Case

Labor Time
3.7 Hrs.**

Labor Description
Two Piece Propeller Shaft
Equipped
(3 - Highly Skilled)
DEF Equipment
2500-3500 4x4 pick-up
only
(3 - Highly Skilled)
4x4 Equipped
(3 - Highly Skilled)

Skill Category
2 - Transmission and
Transfer Case

Labor Time
0.1 Hrs.**

2 - Transmission and
Transfer Case

0.1 Hrs.**

2 - Transmission and
Transfer Case

0.4 Hrs.**

OPTIONAL LOPS:

Labor Operation No:
**21-00-0A-62

21-00-01-69

21-00-0A-60

DIAGNOSIS:
Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in DealerCONNECT/
Service Library, verify all related systems are functioning as designed. If DTCs or symptom conditions, other
than the ones listed above are present, record the issues on the repair order and repair as necessary before
proceeding further with this bulletin.
If a customer’s VIN is listed in VIP or your RSU VIN list, perform the repair. If any vehicle not on the VIN list
exhibits the symptom/condition or DTC, perform the repair.
NOTE: **This is not a proactive repair. This repair is to only be performed under this RSU if the vehicle
exhibits the symptom/conditions listed in this document.**
SPECIAL TOOLS/EQUIPMENT:

Description
wiTECH or Equivalent
End-Play Tool Set
Dial Indicator
Slide Hammers
Puller Adapters

Ref. No.
–
8266B
C-3339A
C-3752
9981

Notes

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J21 FSAR-TSB-4607

SPARE PARTS:

Qty
**1 (AR)

Part No.
68637534AA

Description
K1 Clutch Kit, Automatic
Transmission - Input DIESEL
K1 Clutch Kit, Automatic
Transmission - Input GAS**
Bolt, Hex Head - M12 X
1.50 X 17.80 – Torque
Converter to Flexplate DIESEL
Bolt, Torque Converter to
Flexplate - GAS
Bolt, Front Or Rear
Driveshaft

1 (AR)

68637535AA

6

06511777AA

6

06508406AA

(AR)

06506497AA

(AR)

06509166AA

Bolt, Front Or Rear
Driveshaft

(AR)

05019061AB

(AR)
**1 (AR)
1 (AR)
1 (AR)
1 (AR)

05189966AD
68085955AA
68253940AA
68244579AA
68244638AA

MOPAR® High Temp
Grease
ASRC ATF (Quart)
Gasket, Drain Plug
Ring, Oil Seal
O-Ring
Gasket, Oil Pump**

Notes

Use Star Parts to
determine applicability
by VIN
Use Star Parts to
determine applicability
by VIN

See Caution

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.
NOTE: If a failure has occurred or symptoms are present, complete the repair using the K1 Clutch Kit.
Do not use the Clutch Kits for proactive repairs.

J21 FSAR-TSB-4607

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SPARE PARTS REPLACED ONLY IF NECESSARY:

Qty
(AR)

Part No.
68456960AA

Description
K1 Clutch Hub

(AR)

68253813AB

(AR)

68253770AA

(AR)

68254056AB

Race, K1 Thrust Bearing
Number Two
Roller, K1 Thrust Bearing
Number Two
K2 Clutch Hub

(AR)

68253772AA

(AR)

68253814AA

(AR)

68253815AA

(AR)

68253816AA

(AR)

68269548AA

(AR)

68269549AA

(AR)

68269550AA

K2 Thrust Bearing
Number Three
Race, Selectable Thrust
Bearing - 0.81 mm Diesel
Race, Selectable Thrust
Bearing - 1.10 mm DIESEL
Race, Selectable Thrust
Bearing - 1.60 mm DIESEL
Race, Selectable Thrust
Bearing - 0.81 mm - GAS
Race, Selectable Thrust
Bearing - 1.10 mm - GAS
Race, Selectable Thrust
Bearing - 1.60 mm - GAS

Notes
Replace Only If
Necessary
Replace Only If
Necessary
Replace Only If
Necessary
Replace Only If
Necessary
Replace Only If
Necessary
Replace Only If
Necessary
Replace Only If
Necessary
Replace Only If
Necessary
Replace Only If
Necessary
Replace Only If
Necessary
Replace Only If
Necessary

REPAIR PROCEDURE:
1. **Remove the transmission and DISCARD the torque converter bolts. Refer to the detailed service
procedures available in DealerConnect/Service Library under: 21 - Transmission and Transfer Case /
Automatic - AS69RC / Removal or refer to the detailed service procedures available in DealerConnect/
Service Library under: 21 - Transmission and Transfer Case / Automatic - AS66RC / Removal.
2. Place the transmission manual shift lever into the park lock position.
3. Plug all openings and clean the exterior of transmission with a water soluble solvent, or a pressure washer.

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J21 FSAR-TSB-4607

4. Remove oil pan drain plug Fig. 1 and drain fluid from transmission pan. DISCARD the drain plug gasket.

Fig. 1
Oil Pan Drain Plug
1 - Transmission Oil Drain Plug

DANGER! Be certain the transmission is secure when removing the torque converter, the torque
converter is very heavy. Failure to follow these instructions may result in personal injury
or may be fatal.
5. Remove the torque converter from the transmission Fig. 2.

Fig. 2
Removing Torque Converter
NOTE: Gear train end play is a critical pre-disassembly check to help determine the condition of
the transmission. An end play reading greater than specification (larger gap) indicates that
a bearing or thrust plate is either missing, worn or has disintegrated, in which case there
will be debris found in the transmission oil pan.

J21 FSAR-TSB-4607

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6. Using special tools Adapter Socket, End Play 8266-22 and the handle from End-Play Tool Set 8266B and
Dial Indicator C-3339A, measure and record the input shaft end-play Fig 3.

Fig. 3
Recording The Input Shaft End-Play
1 - 8266-22
2 - 8266B
3 - C-3339A

NOTE: Support the bottom of the transmission case before removing the torque converter
housing.
7. Remove the bolts securing the torque converter housing to the transmission case and remove the housing
Fig. 4.

Fig. 4
Torque Converter Housing And Transmission Case

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J21 FSAR-TSB-4607

8. Remove the bolts securing the oil pump to the transmission case and use Slide Hammers C-3752 with
Adapters 9981 to remove the oil pump assemble from the transmission spline Fig. 5.

Fig. 5
Slide Hammers C-3752 And 9981 Adapters
9. Remove the input shaft assembly with the K1 and K2 clutch assemblies attached Fig. 6.
NOTE: If the K1 snap ring has become dislodged, the K1 clutch assembly will not come out as a
complete unit.

Fig. 6
K1 And K2 Clutch Assemblies
NOTE: If a failure has occurred or symptoms are present, complete the repair using the K1 Clutch
Kit. Do not use the Clutch Kits for proactive repairs.

J21 FSAR-TSB-4607

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10. Remove the K2 clutch assembly and the selectable input shaft end-play thrust bearing number one and
thrust washer from the K1 clutch/input shaft assembly Fig. 7.

Fig. 7
K1 And K2 Clutch Assemblies
1 - K1 Clutch/Input Shaft Assembly
2 - Thrust Bearing Number One
3 - Thrust Washer
4 - K2 Clutch Assembly

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J21 FSAR-TSB-4607

11. Remove and inspect the K1 clutch hub Fig. 8 and Fig. 9. Replace only if needed.

Fig. 8
K1 Clutch Hub
12. Remove and inspect the K1 thrust bearing number two Fig. 10. Replace only if needed.

Fig. 9
K1 Thrust Bearing Number Two

J21 FSAR-TSB-4607

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13. Remove and inspect the K2 clutch hub Fig. 11. Replace only if needed.

Fig. 10
K2 Clutch Hub
14. Remove and inspect the K2 thrust bearing number three. Replace only if needed.
CAUTION!
When installing the thrust washers and bearings be certain they are oriented correctly to the
transmission component. A thrust bearing must be installed correctly or transmission failure may
occur.
NOTE: Apply trans jel or petroleum jelly to all slide portions, rolling contacts surfaces, thrust
surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals
with MOPAR® ASRC ATF. Soak all friction discs in MOPAR® ASRC ATF for at least two
hours before assembly of clutch packs.
NOTE: The input shaft end-play clearance is adjusted by means of a selectable thrust bearing race
located between the K1 and the K2 clutch pack retainers.
15. Lubricate with trans jel or petroleum jelly and install K2 thrust bearing number three Fig. 12.

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J21 FSAR-TSB-4607

Fig. 11
K2 Hub Thrust Bearing Number Three
16. Install the K2 clutch hub into the transmission case Fig. 11.
17. Lubricate with trans jel or petroleum jelly and install K1 thrust bearing number two into K1 Clutch Hub Fig.
10.
NOTE: Bearing/race are separate pieces and they are depicted and described as one Thrust
Bearing.
18. Install the K1 clutch hub and thrust bearing into the transmission case Fig. 10.
19. Apply trans jel or petroleum jelly onto the new input shaft seal rings and install the K2 clutch assembly
onto the new K1 clutch/input shaft assembly with the original selectable input shaft end-play thrust bearing
number one and thrust washer in place Fig. 9.
NOTE: The K2 clutch assembly and the K1 clutch/input shaft assembly must be fully seated onto
the transmission case.
NOTE: The kit contains three NEW selectable input shaft end play thrust bearing number one
options. Use as necessary to achieve the input shaft end play clearance.
20. Install the K2 clutch assembly and the K1 clutch/input shaft assembly into the transmission case Fig. 6.
NOTE: Be certain the input shaft seal rings are in place as well as the seal ring on the oil pump
hub.
21. Lubricate with trans jel or petroleum jelly and install the nylon thrust washer onto the oil pump Fig. 12.
NOTE: The nylon thrust washer is keyed to the oil pump Fig. 12.
NOTE: Two pin punches inserted through the oil pump mounting holes will aid in the installation of
the oil pump Fig. 12.

Fig. 12
Oil Pump Assembly
1 - Oil Pump
2 - Nylon Thrust Washer
3 - Input Shaft Seal Ring

22. Lubricate and install the NEW oil pump O-ring with MOPAR ASRC ATF.
NOTE: Be sure that sealant is cleaned from the threads of the oil pump.

J21 FSAR-TSB-4607

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23. Install the oil pump with a NEW gasket onto the transmission case Fig. 13.

Fig. 13
Oil Pump Assembly On Transmission Spline Shaft
24. Apply a light coating of MOPAR thread sealant onto the oil pump bolts and install the bolts. Tighten the
bolts in a crisscross pattern to 21 N·m (15.5 ft. lbs.).
NOTE: The input shaft end-play clearance is adjusted by means of the selectable number one
thrust bearing race. The Thrust Washer is non-selectable.
25. Install the Dial Indicator Set C-3339A with Input Shaft Spline Socket, End Play 8266-22 and Handle
8266-8, to check the input shaft end-play clearance. The input shaft end-play clearance for both 2WD and
4WD is 0.50 - 0.90 mm (0.019 - 0.035 in.). If the clearance is not within tolerance you must choose
the correct selectable thrust bearing race.
NOTE: The following dimensions below are at time of production.
● Bearing race number one = 0.81 mm (0.031 in.).
● Bearing race number two = 1.10 mm (0.043 in.).
● Bearing race number three = 1.60 mm (0.063 in.).
● End-play spec = 7.62 mm – 22.8 mm (0.300 – 0.900 in.).
26. Assemble and disassemble as necessary to achieve the input shaft end-play clearance.
27. Remove the Dial Indicator set up.
28. Install the torque converter housing to the transmission case.
29. Install the torque converter housing bolts and tighten to 64 N·m (47 ft. lbs.).
DANGER! Be certain the transmission is secure when installing the torque converter, the torque
converter is very heavy. Failure to follow these steps may result in personal injury, or
may be fatal.
30. Install a NEW torque converter lock-up seal located at the nose of the K1 input shaft.
31. Apply trans jel or petroleum jelly onto the new torque converter lock-up seal and new torque converter hub
seal.
32. Install the torque converter onto the input shaft while applying inward pressure and rotating back and forth
at the same time in order to align the input shaft splines and the two teeth on the oil pump drive gear Fig.
2.
33. Install a C-clamp or similar tool to secure the torque converter into the torque converter housing.
34. Using a NEW gasket, install the transmission oil pan drain plug Fig. 1.

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J21 FSAR-TSB-4607

35. Using NEW torque converter bolts, install the transmission. Refer to the detailed service procedures
available in DealerConnect/Service Library under: 21 - Transmission and Transfer Case / Automatic AS69RC / Installation or refer to the detailed service procedures available in DealerConnect/Service
Library under: 21 - Transmission and Transfer Case / Automatic - AS66RC / Installation.
36. Clear all DTCs that may have been set.
37. Using wiTECH, perform a Quick Learn Procedure.**
POLICY:
Reimbursable within the provisions of the warranty.
This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of FCA US LLC.