Technical Service Bulletin (TSB)
Rear Propshaft Clunk
REFERENCE:

TSB: 03-002-25
GROUP: 03 - Differential And Driveline

Date:

April 4, 2025

REVISION: 03-004-24

VEHICLES
AFFECTED:

2021 - 2023 (DT) RAM 1500 Pickup
MARKET APPLICABILITY:
This bulletin applies to vehicles built on or before September 27, 2022
MEA
NA
(MDH 0927XX) equipped with a 6.2L V8 Supercharged Engine (Sales
SA
IAP
Code ESD).
EE

CH

CUSTOMER
SYMPTOM:

Customers may experience the following:
● A clunk noise from the driveshaft while coming to a stop or when just starting to tip into throttle at take off.

CAUSE:

Propshaft defect

This bulletin supersedes Technical Service Bulletin (TSB) 03-004-24, date of issue June 12, 2024,
which should be removed from your files. All revisions are highlighted with **asterisks** and include
an updated Repair Summary, LOP, Spare Parts table, Diagnosis statement, Special Tools table and
Repair Procedure.
This Technical Service Bulletin (TSB) has also been released as a Rapid Service Update (RSU) 22-155,
date of issue August 17, 2022. 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 greasing the rear driveshaft and installing a boot kit.**
CLAIMS DATA:

Labor Operation No:
**16-30-01-9G

Failure Code

Labor Description
Driveshaft, Rear - Grease
and Install Boot Kit
(1 - Semi-Skilled)
ZZ

Skill Category
3 - Differential and
Driveline
Service Action

Labor Time
1.1 Hrs.**

M03 FSAR-TSB-5151

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SPARE PARTS:

Qty
1 (AR)

Part No.
**68597433AA

Description
Boot Kit, Drive Shaft

Notes
Includes Boot, Grease,
Clamps and eight
attaching bolts**

DIAGNOSIS:
**If the customer describes any of the symptoms listed above in the customer symptom section, perform the
Repair Procedure.**
**SPECIAL TOOLS/EQUIPMENT:

Description
Ear Clamp Crimping Tool

Ref. No.
NPN**

Notes

REPAIR PROCEDURE:
1. **Test drive vehicle to confirm the symptom. To isolate the concern: shift the transmission to manual
mode/first gear when coming to a stop. In first gear, while coasting down to a stop, if clunk is still present,
transmission coastdown is eliminated and driveshaft is confirmed as the issue.
2. Is the driveshaft confirmed as the issue?
● YES >>> Proceed to Step 3.
● NO >>> This bulletin does not apply. Normal diagnosis is needed.
3. Raise and support the vehicle. Refer to the detailed service procedures available in DealerCONNECT>
Service Library under: Service Info> 04 - Vehicle Quick Reference/Hoisting/Standard Procedure
4. Remove the driveshaft from the vehicle. Refer to the detailed service procedures available in
DealerCONNECT> Service Library under: Service Info> 03 - Differential and Driveline/ Driveshaft/Shaft,
Drive, Rear/Removal. Discard the removed driveshaft to transfer case bolts and driveshaft to rear
axle flange bolts.
CAUTION!
Do not clean the spline or utilize any grease other than supplied in the service kit. Contamination
with solvents, debris or unapproved lubricants could permanently damage the spline.
5. Carefully remove the large boot clamp from boot seal and pull boot off spline sleeve and separate the two
parts of the driveshaft. Leave boot and small clamp in place unless damaged. If boot is damaged, remove
and discard.
NOTE: ● Protect exposed spline surfaces from contamination during the greasing procedure.
● Do NOT apply grease to the externally splined yoke (transfer case end). Application of
grease to the front portion of the internal spline cavity is sufficient. The grease will
distribute across the length of the spline during reassembly.
6. Use all of the grease from the grease tube to exposed internal spline cavity on the main body of the
driveshaft. Apply grease 360° around inside perimeter of internal spline cavity, approximately one 25 mm
(1 in.) deep.

-3-

M03 FSAR-TSB-5151

7. If original boot was damaged, place a new boot and small clamp from the service kit over the yoke end
shaft and clamp in same position as before removal. Place the new large clamp (supplied in kit) loosely
over boot on tube end - Do not secure clamp yet.
CAUTION!
The spline will only reassemble freely in the original spline orientation. Do not force assembly with
the spline out of rotational alignment. Misaligned assembly will result in noise or vibration.
8. Reassemble the main body of the driveshaft to the yoke and boot assembly.
9. Using a suitable ear clamp crimping tool, securely crimp the large boot clamp to the driveshaft.
10. Using new bolts, install the driveshaft. Refer to the detailed service procedures available in
DealerCONNECT> Service Library under: Service Info> 03 - Differential and Driveline/Driveshaft/Shaft,
Drive, Rear/ Installation.
11. Remove vehicle from hoist and test drive to confirm repair.**
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.