• Whistle while truck is moving (not turbo noise) - loose radio antenna
• Chirp or clunk from front end when driving over bumps
  • bad lower ball joint, track bar, and/or intermediate steering shaft
  • loose lower shock bolt
• Hissing from front of truck after engine turned off - normal; a result of pressure in AC condenser bleeding off. NOTE: AC runs in many positions of the selector switch.
• Grinding or "Impact wrench" sound that gets louder with engine load - Transfer case output shaft snap ring broken allows shaft assembly to move backward and grind into the case.
• Squeak from steering column or front end while turning steering wheel - Lube the U-joint in the steering shaft (under the hood).
• Flapping sound from front of truck
  • Rubber baffle (radiator protector) under/behind bumper loose
  • Diesel: Air intake snorkle from fender to air filter collapsing - remove it

• HVAC control intermittent, air vents change themselves -
• all engines: check for vacuum leak(s)
• all engines: TSB 24-01-96A  bad or missing HVAC vacuum check valve
• diesel only: TSB 24-16-96  oil contamination of vacuum lines
• HVAC system has musty or moldy odor
• TSB 24-11-97 clean AC evaporator
• Use Lysol to clean the system - tip posted to the RTML
• Cruise Control inoperative
• TSB 08-22- 97  leaking vacuum hose at speed control servo due to battery acid on the servo hose
• Fan noise and low air volume - The return air duct can be partially blocked by items that fell from the back of the glove box.

TRANSMISSION / CLUTCH

• NV5600 shift pattern on knob rotates - use a small screwdriver to pry it out and reseat it.
• NV5600 shift knob loose/rattling - Tighten the shift knob:
  • Use a tiny screwdriver to pry the shift pattern piece out of the shift knob.
  • Use a 15mm socket to loosen the locknut, screw the knob down until tight.
  • Retighten the locknut and pop the shift pattern back into the knob.
• NV5600 6 speed leaking oil - loose shift tower bolts on top of transmission
• NV5600 6 gear grind when shifting into 3rd - DC is working on the problem - update page.
• 2000+ Models with loose transmission bolts - Reports of loose transmission, bellhousing, trans mount, and crossmember bolts have appeared on the TDR forum. Check your bolts!
• NV4500HD OD failure - 5th gear nut vibrates loose  TSB 21-10-98a  replace nut
• IMPORTANT: To prevent OD failure,  do not pull or haul loads in OD at engine speeds below 1600rpm.
• The real fix is the Standard Transmission fully splined mainshaft
• V10 Manual transmission rattle - TSB 21-13-97 - replace clutch disk and propshaft
• Launch shudder - 2X4 REGULAR CAB 3/4 models - 
• TSB 03- 02-96 change the 2 piece drive shaft to a 1 piece
• Clunk from transmission when shifting into forward or reverse
• reports to RTML are that the transmission must be rebuilt if customer complains
• Shifter noise and/or rattle - loose knob retainer nut
  • Pry out the plastic gear shift diagram. Under that is a 14mm hex nut. Loosen it with a deep socket. Then make sure the shifter knob is screwed on as far as it will go. Then tighten the 14mm locknut.

Clutch

• Soft pedal or transmission hard to shift - tests to determine the cause.

Transfer case shifter noise and vibration -

• Anything laying in the shifter boot will create/add noise.
• TSB 21-13-96 Reinstall plastic gate liner - superseded by 21-13-97
• TSB 21-13-97  Install plastic gate liner
• TSB  21-12-97 advises bending a bracket near the shifter.
• Also see RTML notes  from Joe Donnelly, Hues11, and Bob Bergevin.
• 98+ remove the screws from the shifter boot and stuff an 8 ounce bag of Soft Touch Poly-fill Supreme (typically used for stuffing dolls and car stereo speaker enclosures) into the shifter and the 4WD selector space. (from the TDR Forum)
• Taming Some Tough Transfer Case Problems = NV241 tech article on the ATRA and GEARS magazine site

Shudder while turning in 4WD Mode - Don't drive a Ram in 4X4 while on a dry and hard road surface! Chrysler gets many complaints from people who do not understand that a part time 4WD system is not meant for hard surfaced roads. For shudder conditions when off road or in winter weather: Document the weather conditions, when it happens, on what type of surface, gear used, hi/low range used, how long in 4WD, amount of throttle used, etc to help the service technicians reproduce the shudder.

ELECTRICAL

• Excessive current draw with key off (high IOD) - Seat Belt Control Module keeps seat belt solenoids engaged which draws almost .5A continuously. If the solenoids remain activated for more than 20 minutes, replace the module with a revised part..
• Battery is dead due to glove box light staying on - TSB 08-35-97 Install spacers on glove box lamp switch.
• Battery does not charge 1996-1998 - Disconnecting the black connector from the PCM without first waiting for the key to be in the OFF position for at least 5 seconds can, under certain key-on or key-off scenarios, cause the PCM to write information to the EEPROM chip, which then sets the target charging voltage to zero. The PCM must be relaced to restore charging capability.

• Fuel gauge inaccurate, sender in tank bad - very common; replace sender or DIY repair instructions

• Failure to crank 2000-2001 - see service action #00-01 for fuse revision
• Failure to crank and/or starter runs when key released - burned solenoid contacts. Repair parts and instructions available on Foster Truck acc page
• No crank with key held in start position 1994-1997
  • TSB 08-21-97 check B+ terminal on starter solenoid and retighten to 120 in/lbs
  • battery dead - they die without warning

• Noisy windshield wiper 1998-1999 with RKE (keyless entry) - A quieter wiper assembly PN 55076549AG is available. When the module is installed, the CTM must be reflashed as discussed in TSB 08-43-99.

• High Beam indicator remains lit with lights on low beam 1998-1999 - even after replacing the printed circut
  • revised part #  1998 models use 5602061AC, 1999 models use 56020618AE.
• Lights flickering 1998-2002 diesel
  • Lights will normally brighten and dim at idle as intake heater grid cycles on/off
  • poor connection on the intake air temperature sensor connector - clean pins and reassemble
  • Charge cycle unstable - replace PCM
  • Bad intake manifold heater solenoids - replace
  • Loose wires on intake manifold heaters - tighten connections
• fog lamps don't stay on -
• TSB 08-11-98  wiring change
• 98-02 Headlamp switch hot - normal heat dissipation from instrument light dimmer.
  • If it bothers you, remove the headlight switch and punch a 5/16" hole in the top of the air duct under the dimmer wheel to cool the dimmer heatsink.

• overdrive and speed control problems
  • Star Center News - Aftermarket Alarm can cause strange problems
• Compass does not display correctly - Star Center News diagnostics
• remote keyless entry (RKE) transmitter batteries discharge in 6 weeks +/-
  • TSB 08-39-97 replace the transmitter and reprogram to match vehicle
• Checking electrical sensors = part 1 general test procedures on the ATRA and GEARS magazine site
• Checking electrical sensors = part 2 general test procedures on the ATRA and GEARS magazine site
• Checking motors, relays, and solenoids = general test procedures on the ATRA and GEARS magazine site
• Speed sensor diagnostics = general test procedures on the ATRA and GEARS magazine site

SUSPENSION

• Clunk From Bed Area - common on trucks w/ helper springs as the helpers hit the spring bumpers, live with it.
  • Noise can be reduce by installing 3" rubber plumbing couplings (known as Fernco Couplings) on the stops.
• Creaking Noise coming from the rear of the vehicle
• TSB 02-03-96 - replace missing spring tip insert
• Speedometer Clicking -
• TSB 08-23-96   Replace speedometer.
• Front End Clunk -
• Loose shock absorber bolts
• worn stabilizer bar end links
• incorrect stabilizer bar end links
• 1994, 1995 4x4 4x2 chassis cabs  TSB 02-05-95  replace with tapered ball stud links
• worn factory shocks (they die young - replace by 20,000 miles!)
• Loose lower shock bolts - very common