Technical Service Bulletin (TSB)
Rear Selective Thrust Washer Failure
REFERENCE:

TSB: 21-010-25
GROUP: 21 - Transmission and Transfer
Case

Date:

January 16, 2025

REVISION: 21-054-24 REV. E

VEHICLES
AFFECTED:

2024 (D2) RAM 3500 Pickup
MARKET APPLICABILITY:
2024 (DJ) RAM 2500 Pickup
MEA
NA
This bulletin applies to vehicles built on or after June 14, 2024 (MDH
SA
IAP
0614XX) and on or before September 04, 2024 (MDH 0904XX) equipped
with the 6.7L I6 Cummins Turbo Diesel Engine (Sales Code ETL) and a
EE
CH
6-Spd Automatic 68RFE Transmission (Sales Code DG7).

CUSTOMER
SYMPTOM:

This is a proactive RSU Repair Procedure to be performed for all Unsold vehicles not exhibiting any
Diagnostic Trouble Codes (DTCs) or Customer Symptoms. The Malfunction Indicator Lamp (MIL) should
not be illuminated.
If a customer’s VIN is listed in your RSU VIN list, does not have the MIL illuminated and does not exhibit
any customer symptom/conditions, perform the repair.
For all other vehicles with the MIL illuminated or exhibiting any customer symptoms/conditions, this
service action does not apply. Please follow normal diagnostic and repair procedures.

CAUSE:

Rear selective thrust bearing cracking

This bulletin supersedes Technical Service Bulletin (TSB) 21-054-24 REV. E, date of issue December
12, 2024, which should be removed from your files. All revisions are not highlighted with **asterisks**
and include removal of the SA market from Market Applicability.
This Technical Service Bulletin (TSB) has also been released as a Rapid Service Update (RSU) 24-161,
date of issue December 03, 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.

J21 FSAR-TSB-4966

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REPAIR SUMMARY:
This bulletin involves replacing the transmission 4C clutch hub/reaction sun gear assembly and the 4C clutch
hub/reaction sun gear assembly rear selective thrust plate/shim.
VINs identified as being involved in this campaign are currently live and searchable. Stop Sale is in effect for
the above-identified vehicles.
NOTE: Some of the involved vehicles may be in dealer new vehicle inventory. Involved vehicles can be
determined by using the VIP inquiry process.
CLAIMS DATA:

Labor Operation No:
21-00-19-90

Failure Code

Labor Description
Bearing, Transmission
Thrust - Replace
(3 - Highly Skilled)
ZZ

Skill Category
21 - Transmission

Labor Time
4.2 Hrs.

Service Action

RELATED LOPS:

Labor Operation No:
21-00-19-67
21-00-19-68

Labor Description
4x4 Equipped
(3 - Highly Skilled)
Skid Plate Equipped
(3 - Highly Skilled)

Skill Category
21 - Transmission

Labor Time
1.0 Hrs.

21 - Transmission

0.1 Hrs.

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J21 FSAR-TSB-4966

SPARE PARTS:

Qty
1
1

Part No.
52119771AB
05013092AB

6
8

06508406AA
06506497AA

1
18

68433227AB
68218057AC

1
15

68425659AA
06102403AA

1
1
1

04799964AD
52119645AA
06504548

Description
Gear, Reaction Sun
Plate Package, Planetary
Thrust
Torque Convertor Bolts
Hex Flange Head Locking
Bolt
Front Driveshaft Boot Kit
Fluid, Auto Transmission
ATF+4, Quart, Standard
MS 9602-F
Gasket, Oil Pan
Bolt, Hex flange Head M6
x 1 x 14
Seal, Sump Filter
Cover, Oil Pump
Screw, M6 x 1 x 30

Notes
Rear Selected Thrust
Plate/Shim Package
Front and Rear Driveshaft
Bolts

With Seals and O-ring
Manual Shift Lever Bolt

DIAGNOSIS:
If a customer’s VIN is listed in your RSU VIN list, does not have the MIL illuminated and does not
exhibit any customer symptom/conditions, perform the repair.
For all other vehicles with the MIL illuminated or exhibiting any customer symptoms/conditions, this
service action does not apply. Please follow normal diagnostic and repair procedures.

J21 FSAR-TSB-4966

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SPECIAL TOOLS/EQUIPMENT:

Description
Support Stand Tool
End-Play Tool Set
Adapter
Dial Indicator
Alignment Plate
Output Shaft End-Play Socket
End-Play Tool Set Handle
wiTECH or Equivalent

Ref. No.
8257
8266-17
8216
C-3339A
10065
8266-20
8266B
-

Notes

REPAIR PROCEDURE:
NOTE: The rear transmission end-play must be set as the 4C clutch hub/reaction sun gear is being
replaced in addition to the rear selected thrust plate/shim.
CAUTION!
Tag all snap rings, thrust washer, washers, shims, spacers and thrust bearings, etc. during
disassembly for quick identification and assembly. Failure to follow these instructions will cause
damage and transmission failure.
NOTE: During assembly, apply trans jell 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® ATF+4. Soak all friction disks in MOPAR® ATF+4 for at least
two hours before assembly of clutch packs.
68RFE Clutch Orientation Fig. 1:

Fig. 1
68RFE Clutch Orientation
1 - U/D Clutch
2 - O/D Clutch
3 - Reverse Clutch
4 - 4C Clutch
5 - 2C Clutch
6 - L/R Clutch

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J21 FSAR-TSB-4966

1. Is the vehicle on the RSU VIN list?
● YES >>> Proceed to Step 2.
● NO>>> This RSU bulletin does not apply. Normal diagnosis should be performed.
2. Remove the torque converter from the transmission. Refer to the detailed service procedures available in
DealerCONNECT/Service Library under: Service Info> 21 - Transmission and Transfer Case / Automatic 68RFE / Torque Converter / Removal.
3. Remove the manual shift lever from the transmission and DISCARD the manual shift lever bolt Fig. 2.

Fig. 2
Manual Shift Lever
1 - Manual Shift Lever

4. Remove the input speed sensor from the transmission case Fig. 3. Refer to the detailed service
procedures available in DealerCONNECT/Service Library under: Service Info> 21 - Transmission and
Transfer Case / Automatic - 68RFE / Sensor, Speed, Input / Removal.

Fig. 3
Removal - Input Sensor
1 - Output Speed Sensor (Do Not Remove)
2 - Line Pressure Sensor
3 - Input Speed Sensor

J21 FSAR-TSB-4966

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5. Install Support Stand 8257 onto the transmission case Fig. 4.

Fig. 4
Support Stand Tool 8257
1 - Support Stand Tool 8257

6. Using Adapter 8266-17 from End-Play Tool set 8266B and Dial Indicator C-339A, measure and record the
input shaft end-play Fig. 5.

Fig. 5
Measure Input Shaft End Play
1 - End-Play Tool Set 8266-17
2 - Adapter 8216 With Dial Indicator C-3339A

NOTE: When measuring the input shaft end-play, two "stops" will be felt. When the input shaft
is pushed inward and the dial indicator zeroed, the first "stop" felt when the input shaft
is pulled outward is the movement of the input shaft in the input clutch housing hub.
This value should not be included in the end-play measured value and therefore must be
recorded and subtracted from the dial indicator reading.
NOTE: Adapter 8266-17 will fit loosely onto the input shaft, this should not effect the performance
of the adapter.

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J21 FSAR-TSB-4966

7. Remove the bolts holding the transmission extension/adapter housing to the transmission case.
8. Remove the extension/adapter housing from the transmission case.
9. Using Alignment Plate 10065, Output Shaft End-Play Socket 8266-20, handle from End-Play Tool Set
8266B and Dial Indicator C-339A, measure and record the output shaft end-play Fig. 6.

Fig. 6
Measure Output Shaft End Play
1 - Tool 10065
2 - Tool 8266-20
3 - Tool C-3339A

10. Remove the bolts holding the transmission oil pan to the transmission case.
11. Remove the transmission oil pan from the transmission case and DISCARD the oil pan gasket.
12. Remove the valve body from the transmission case. Refer to the detailed service procedures available
in DealerCONNECT/Service Library under: Service Info> 21 - Transmission and Transfer Case/Automatic/
Valve Body/Removal and Installation.

J21 FSAR-TSB-4966

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13. Remove the outer snap-ring securing the transmission front cover into the transmission case Fig. 7.

Fig. 7
Front Cover
1 - Front Cover
2 - O-Ring
3 - Snap Ring
4 - Front Cover Seal

14. Reaching through a case opening in the valve body area with a long blunted Tool, remove and DISCARD
the transmission front cover from the transmission case Fig. 7.

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J21 FSAR-TSB-4966

15. Remove the bolts holding the oil pump into the transmission case Fig. 8.

Fig. 8
Remove Oil Pump
1 - Oil Pump To Case Bolt
2 - Oil Pump

16. Remove the oil pump. Hold inward on the input shaft to prevent pulling the input clutch assembly with the
oil pump Fig. 8.
CAUTION!
If the input shaft is not held during oil pump removal, the input clutch assembly will attempt
to move forward with the oil pump and the numbers 2, 3, or 4 bearings inside the input clutch
assembly may become dislodged.

J21 FSAR-TSB-4966

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17. Remove the number one thrust bearing from the input clutch assembly Fig. 9.

Fig. 9
68RFE Cross Sectional
1 - Thrust Bearing No. 1

8 - Thrust Bearing No. 8

2 - Thrust Bearing No. 2

9 - Thrust Bearing No. 9

3 - Thrust Bearing No. 3

10 - Thrust Bearing No. 10

4 - Thrust Bearing No. 4

11 - Thrust Bearing No. 11

5 - Thrust Bearing No. 5

12 - Thrust Bearing No. 12

6 - Thrust Bearing No. 6

13 - Output Shaft Bearing

18. Remove the input clutch assembly from the transmission case Fig. 10.

Fig. 10
Input Clutch Assembly
1 - Thrust Bearing Number 5
2 - Rear Selected Thrust Plate/Shim
3 - Input Clutch Assembly
4 - Thrust Bearing Number 1

19. Remove the number 5 thrust bearing and rear selected thrust plate/shim from the input clutch assembly, or
the 4C clutch retainer/bulkhead Fig. 10.

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J21 FSAR-TSB-4966

20. Remove the 2C/4C clutch retainer/bulkhead tapered snap-ring from the transmission case Fig. 11.

Fig. 11
2C/4C Clutch Retainer/Bulkhead
1 - Snap-Ring
2 - 2C/4C Clutch Retainer/Bulkhead

21. Remove the 2C/4C clutch retainer/bulkhead from the transmission case Fig. 11.
22. Remove the front 2C clutch pack snap-ring from the transmission case Fig. 12.

Fig. 12
2C Clutch Pack
1 - Snap-Ring

3 - Disc

2 - Plate

4 - Reaction Plate

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23. Remove the 2C clutch pack from the transmission case Fig. 12.
24. Remove and DISCARD the rear selective thrust plate/shim from the 4C clutch hub/reaction sun gear
assembly Fig. 13.

Fig. 13
Reaction Annulus And Carrier
1 - Thrust Bearing Number 6
2 - Output End Play Rear Selected Thrust Plate/Shim
3 - 4c Clutch Hub / Reaction Sun Gear Assembly
4 - Thrust Bearing Number 8
5 - Reaction Planetary Carrier
6 - Thrust Bearing Number 9

25. Remove and DISCARD the 4C clutch hub reaction sun gear assembly Fig. 13.
26. Install the 2C reaction plate Fig. 14.

Fig. 14
2C Clutch Pack
1 - Snap-Ring
2 - Plate
3 - Disc
4 - Reaction Plate

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J21 FSAR-TSB-4966

27. Install the 2C clutch pack into the transmission case Fig. 14.
28. Install the flat 2C/4C clutch snap-ring into the transmission case Fig. 14.
29. Install the reaction planetary gear set.
30. Install the number 8 thrust bearing into the 4C clutch hub reaction sun gear assembly with the blue ink
stripe against the sun gear with the inner race facing up Fig. 15.

Fig. 15
Reaction Annulus And Carrier
1 - Thrust Bearing Number 6
2 - Output End Play Rear Selected Thrust Plate/Shim
3 - 4C Clutch Hub / Reaction Sun Gear Assembly
4 - Thrust Bearing Number 8
5 - Reaction Planetary Carrier
6 - Thrust Bearing Number 9

31. Install NEW output shaft rear selected thrust plate/shim onto the NEW 4C clutch hub/reaction sun gear
assembly with the oil grooves facing the hub and the lugs and notches aligned as shown Fig. 16.

Fig. 16
Thrust Plate Alignment
1 - Locating Lugs
2 - Rear Selected Thrust Plate/Shim

NOTE: The angular spacing between the lugs/notches is not uniform.

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32. Install the number 6 thrust bearing against the NEW output shaft rear selected thrust plate/shim with
the flat side against the thrust plate/shim and the raised tabs on the inner race facing the front of the
transmission Fig. 17.
NOTE: Use the thinnest rear selected thrust plate/shim initially to avoid part damage. The correct
and final sized end-play shim is determined in Step 37.

Fig. 17
Reaction Annulus And Carrier
1 - Thrust Bearing Number 6
2 - Output End Play Rear Selected Thrust Plate/Shim
3 - 4C Clutch Hub / Reaction Sun Gear Assembly
4 - Thrust Bearing Number 8
5 - Reaction Planetary Carrier
6 - Thrust Bearing Number 9

NOTE: The rear transmission end-play must be set as the 4C clutch hub/reaction sun gear
assembly is being replaced in addition to the rear selected thrust plate/shim.
33. Install the NEW 4C clutch hub/reaction sun gear assembly into the reaction planetary gear set Fig. 17.
34. Install the 2C/4C retainer/bulkhead into the transmission case Fig. 18. Make sure that the oil feed holes
are pointing toward the valve body area. Rotate the 4C clutch hub/reaction sun gear assembly during the
installation of the 4C retainer/bulkhead to ease installation.

Fig. 18
4C Clutch Retainer/Bulkhead
1 - Snap-Ring
2 - 2C/4C Clutch Retainer/Bulkhead

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J21 FSAR-TSB-4966

35. Install the 2C/4C retainer/bulkhead tapered snap-ring into the transmission case with the taper toward the
front of the case. Make sure that the open ends of the snap-ring are located in the case opening toward the
valve body area Fig. 19.

Fig. 19
Case Opening Snap Ring Location
1 - Snap-Ring
2 - Case Opening

36. Air check the 2C and 4C clutch operation. Refer to the detailed service procedures available in
DealerCONNECT/Service Library under: Service Info> 21 - Transmission and Transfer Case/Automatic
- 68RFE - Diagnosis and Testing.
37. Using Alignment Plate 10065, Output Shaft End-Play Socket 8266-20, handle from End-Play Tool Set
8266B and Dial Indicator C-3339A, measure and record the output shaft end-play. The correct output shaft
end-play is 0.25-0.52 mm (0.010-0.020 in.). Adjust as necessary by installing the chosen output shaft
selective rear selected thrust plate/shim and re-measure the end-play to verify selection Fig. 20.
Output Shaft End Play Rear Selected Thrust Plate/Shim Thickness:
●
●
●
●
●
●
●
●
●
●
●

09 = 2.18 mm (0.086 in.)
10 = 2.33 mm (0.092 in.)
11 = 2.48 mm (0.098 in.)
12 = 2.63 mm (0.103 in.)
13 = 2.78 mm (0.109 in.)
14 = 2.69 mm (0.115 in.)
43 = 3.08 mm (0.121 in.)
16 = 3.23 mm (0.127 in.)
17 = 3.38 mm (0.133 in.)
18 = 3.53 mm (0.139 in.)
19 = 3.68 mm (0.145 in.)

NOTE: The output shaft end play is adjusted by means of a selectable rear selected thrust plate/
shim in front of the 4C clutch hub/reaction sun gear assembly. The selectable rear selected
thrust plate/shim thickness is identified by a numeric numeral molded or stamped into the
spacer.

J21 FSAR-TSB-4966