I have a 2005 3.5L V6 SXT. Almost 2 weeks ago I found out I had water in my transmission after experiencing RPM over 3,000 going 60 MPH before shifting. Was told that the problem was my dipstick tube was loose where it connects to the transmission. They sealed that and flushed the fluid and changed filter several times over a few days. Ever since then I have been experiencing a vibration at 30-50 MPH. If I romp on it I don't get the vibration. However on city streets, in traffic, etc I get the vibration. Was told my tie rods are bad and need replacing but they can't guarantee that will fix the vibration. Anyone else with this problem? I am at my wits ends on this! I don't want to go replacing parts on a chance they will fix the problem but that is where I am at unless I decide to just drive it until something breaks. I don't want to cause more damage but also can't afford unnecessary repairs either.

 

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 DaimlerChrysler Corporation.
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-011-05 REV A, DATED JULY
14, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE
REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT:
Dipstick Tube Seal May Leak Causing ATF Contamination Or Transmission Shudder/Buzz
OVERVIEW:
This bulletin involves tests to be performed on the transmission to determine the integrity
of the transmission oil fill tube seal. Dependent upon test results: the oil tube seal will
require replacement, the transmission may require a flush procedure, and/or the
transmission torque converter may require replacement.
MODELS:
2005 - 2006 (LX/LE) 300/Magnum/Charger
NOTE: This bulletin applies to LX/LE vehicles equipped with a NAG1 transmission
(sales code DGJ) that were built prior to December 2005 with a
TRANSMISSION build date of July 08, 2005.
SYMPTOM/CONDITION:
Water may leak past the transmission oil fill tube (dipstick tube) seal. Dependent upon the
amount of water accumulation in the transmission oil, the customer may experience a
transmission shudder vibration and/or an audible high frequency buzz-like sound. The
shudder vibration or buzz-like sound may be most noticeable during light acceleration
where partial application of the torque converter clutch (TCC) in 3rd, 4th, or 5th gear
occurs.
The shudder/buzz condition may be due to the torque converter clutch and a “stick-slip”
condition caused by contaminated transmission oil/fluid. The transmission fluid
contamination may be caused by water intrusion past the transmission fill tube seal.
DIAGNOSIS:
1. Determine if the original transmission fill tube seal has been previously replaced with
fill tube seal p/n 05189087AA (or later).
2. Has the transmission oil fill tube seal been replaced with p/n 05189087AA (or later)?
a. If YES >> STOP. This bulletin does not apply. Further diagnosis is required.
b. If NO >> Proceed to the next step.
NUMBER: 21-003-06
GROUP: Transmission
DATE: February 18, 2006
The transmission has a transmission part and serial number label which is located on the
left (driver) side of the transmission above the transmission oil pan (Fig. 1). The bottom (11
digit) number on the label is the transmission part number. The TOP NUMBER (14 digit)
on the label is the transmission SERIAL NUMBER. The date that the transmission was
built can be obtained from the serial number (example: TxxxxxDDDYxxxxx). The
transmission build date is in Julian calendar format which uses a 3 digit number to
represent the day of the year and a 1 digit number to represent the calendar year. In the
serial number: the 6th, 7th, and 8th number (3 digits) represent the Julian day, and the 9th
number (1 digit) represents the year (in Julian date format). Example: TI2TJ 0015xxxxx
shows that the transmission Julian build date is “0015”. The numbers “001” in date “0015”
equals the first day of the calendar year, or January 1st. The number “5” in date “0015”
equals the calendar year, in this case the year 2005. A serial number of Txxxx1895xxxxx
has a Julian date of “1895”. “189” equals July 8th, and “5” equals the year 2005.
NAG1 transmissions built prior to a Julian date of 1895 (July 08, 2005) may have
suspect fill tube seals.
3. Determine the transmission build date (Julian date) of the transmission by inspection
of the serial number on the transmission part and serial number label.
4. Was the transmission built prior to July 08, 2005, Julian date 1895?
a. If YES >> Perform the Repair Procedure
b. If NO >> STOP. This bulletin does not apply. Further diagnosis may be necessary.
Fig. 1 Transmission Part And Serial Number Location
1 - IDENTIFICATION NUMBERS MAY BE STAMPED INTO OIL PAN FLANGE.
21-003-06 -2-
PARTS REQUIRED:
Qty. Part No. Description
1 05189087AA Seal, Fill Tube
1 68001278AA O-Ring, Transmission 13-Way Connector Guide
Bushing (Large)
1 68001279AA O-Ring, Transmission 13-Way Connector Guide
Bushing (Small)
(AR) 6 NPN Rivet, Black Plastic 3-Leg (6.25 x 25.00 mm)
1 05191804AA Leak Detection Fluid (8 oz. can be used to perform 4
repairs)
1 04897150AB or
04897151AB
Mopar Brake Parts Cleaner
(AR) 05013457AA Fluid, Automatic Transmission (MS-9602 / ATF+4 /
Quart)
(AR) 05013458AA Fluid, Automatic Transmission (MS-9602 / ATF+4 /
Gallon)
(AR) 1 52108325AA Filter, Transmission Oil
(AR) 1 05137631AA Torque Converter - 2005 - 2006 LX/LE (RWD or AWD)
with a 5.7L or 6.1L engine
(AR) 1 05143212AA Torque Converter - 2005 LX/LE (AWD) with a 3.5L
engine
(AR) 1 05174299AA Torque Converter - 2006 LX/LE (RWD or AWD) with a
3.5L engine.
SPECIAL TOOLS / EQUIPMENT:
9336 Transmission Oil Dipstick
CH9401 StarSCAN® Tool
CH9404 StarSCAN® Vehicle Cable
8875A Transmission Cooler Line Disconnect
9902 Fill Tube Oil Seal Installation Disc
W-18-MIL-1146AS Air Pressure Regulator (w/hose)
NPN 6 inch “C” Clamp
NPN Straight End and Scale/Ruler (to measure and verify torque
converter depth to transmission)
-3- 21-003-06
REPAIR PROCEDURE:
A. Air Pressure Test - Transmission Fill Tube Oil Seal:
1. Place the vehicle on a suitable lift.
2. Open the hood and remove the transmission oil fill tube cap.
3. Connect the air pressure regulator hose to the transmission fill tube. Do not connect
shop air to the regulator at this time (Fig. 2).
4. Verify that the regulator air pressure setting is turned all the way counterclockwise.
This will provide minimal air pressure to the transmission.
CAUTION: Never allow the air pressure inside the transmission to exceed 34 kPa (5
psi). This could cause transmission oil seal damage or separation the
transmission vent cap from the transmission case.
Fig. 2 AIR PRESSURE REGULATOR
1 - Transmission Oil Fill Tube
2 - Air Regulator Adapter Hose
3 - Air Regulator - Set To 14 kPa (2 psi) - DO NOT exceed 34 kPa (5 psi)
4 - Shop Air Supply Hose
5. Connect shop air to the pressure regulator.
6. Adjust the pressure regulator by turning the adjustment **** clockwise until the
regulator gauge reads 14 kPa (2 psi).
NOTE: A hissing sound may be heard from the transmission vent. This is a normal
condition.
7. With the transmission pressurized to 14 kPa (2 psi), raise the vehicle.
21-003-06 -4-
8. Apply the leak detection fluid (or suitable soapy solution) around the top of the
transmission fill tube oil seal. Inspect for air leakage (bubbles) between the oil
seal-to-fill tube connection, and between the oil seal-to-transmission housing
connection (Fig. 3).
NOTE: On some seals with a large leak path, the leak detection fluid may be blown
off the seal by the escaping air before the fluid has a chance to bubble.
9. Does the transmission oil fill tube seal leak air when properly pressurized?
a. If YES >> Proceed to Section B - Road Testing The Vehicle For Torque Converter
Shudder/Buzz.
b. If NO >> Proceed to Section C - Fill Tube Oil Seal Replacement.
Fig. 3 LEAK CHECK SEAL
1 - Transmission Oil Fill Tube
2 - Leak Detection Fluid - Applicator Nozzle
3 - Transmission Oil Fill Tube Seal
B. Road Testing The Vehicle For Torque Converter Shudder/Buzz:
WARNING:Have an assistant drive the vehicle during the vehicle road test, while the
technician operates the StarSCAN® scan tool and monitors its data.
Obey all traffic regulations. A smooth black top pavement is the preferred
road surface for evaluation. The vehicle will need to be accelerated
safely, at light throttle, from 56 to 80 km/h (35 to 50 mph).
NOTE: The shudder/buzz condition is usually much more detectable while the
transmission is cold (below normal operating temperature).
-5- 21-003-06
1. Connect the StarSCAN® scan tool to the vehicle Data Link Connector (DLC).
2. Using the StarSCAN®, navigate to the ECU view, select TCM EGS 52, and select the
Data Display screen.
3. Scroll to the Torque Converter Clutch (TCC) data information screen. The screen will
display the following:
a. “TCC Duty Cycle”
b. “TCC Status”
c. “TCC Actual Slip”
d. “TCC Desired Slip”
e. “TCC Setpoint Pressure”
f. “Actual Gear”
g. “Target Gear”
4. With an assistant driving, accelerate the vehicle to 56 km/h (35 mph).
5. Verify that the transmission (“Actual Gear”) is in either 4th or 5th gear.
6. Continue slowly accelerating the vehicle until the “TCC Status” changes from “OPEN”
to “SLIP” mode.
7. While the transmission is in 4th or 5th gear and in “SLIP” mode, carefully evaluate the
vehicle for the presence of a shudder vibration or an audible high frequency buzz-like
sound. The shudder/buzz is most noticeable in 4th or 5th gear at vehicle speeds
between 64 to 80 km/h (40 to 50 mph).
a. Under normal operation, the “TCC Actual Slip” value will change/modulate between
40 to 80 RPM's of slip.
b. When the shudder/buzz condition is present, the “TCC Actual Slip” value will
change/modulate between 0 to 80 RPM's of slip. At 0 RPM's the TCC is not slipping
as intended (sticking). The change between 0 RPM's and 80 RPM's may cause a
“stick slip” shudder condition and/or an associated vibration induced buzz-like
sound.
8. The shudder/buzz condition may not occur during the first evaluation attempt. Repeat
steps 4 through 7 three more times to confirm the shudder/buzz condition. The engine
and transmission may need to be brought up to normal operating temperatures to
thoroughly diagnose. It is important to make certain that the transmission
shudder/buzz condition is caused by the stick-slip of the transmission torque
converter, and not some other vehicle component.
9. Did the road test confirm the presence of a transmission torque converter clutch
shudder/buzz condition when the torque converter was in its “SLIP” mode?
a. If YES >> Proceed to Section D - Torque Converter Replacement. The torque
converter must be replaced and the old transmission oil thoroughly flushed from the
transmission.
b. If NO >> Proceed to Section E - Transmission Oil Drain. The old transmission oil
must be thoroughly flushed from the transmission. The torque converter does not
require replacement.
NOTE: If the shudder/buzz condition occurs when the transmission torque converter
is NOT in “SLIP” mode, then this Service Bulletin does not apply and further
diagnosis is required.
C. Fill Tube Oil Seal Replacement:
1. If not already performed, remove the two transmission oil fill tube fasteners.
2. If not already performed, lift the fill tube out of the transmission case.
3. If not already performed, using a short screwdriver, pry the old fill tube oil seal out of
the transmission case.
21-003-06 -6-
4. From the outside of the new seal, pierce the center of the seal surface with a small
screwdriver along the molded “Y”. This will make installing the transmission fill tube
easier.
5. Install the new fill tube oil seal into the fill tube bore on the transmission case. Push the
seal in by hand until bottomed.
NOTE: The seal cannot be fully installed by hand. The seal installer disc and “C”
clamp must be used to fully seat the fill tube oil seal.
6. Seat the new fill tube oil seal using the seal installer disc (Special Tool 9902) and a 6
inch “C” clamp (Fig. 4).
CAUTION: Do not over tighten the “C” clamp during fill tube oil seal installation.
Transmission oil pan damage or bending could occur.
NOTE: A piece of shim stock can be placed between the transmission oil pan and
the “C” clamp to further eliminate the chance of damaging or bending the oil
pan.
Fig. 4 INSTALL SEAL WITH C-CLAMP
1 - Transmission Oil Pan - Protect Pan By Placing Shim Stock Between Clamp Foot And Pan
2 - Seal Installer Disc (Special Tool 9902) - Use To Fully Seat Seal To Transmission
3 - 6 inch C-Clamp
4 - DO NOT OVERTIGHTEN - C-Clamp Foot Must Be At Edge Of Pan
5 - Lightly Tighten C-Clamp Until Seal Installer Disc Bottoms At The Transmission Case
7. Clean the end of the fill tube with a shop cloth. Then lightly lubricate the fill tube end
with transmission oil and install the tube into the seal.
-7- 21-003-06
8. Install both fill tube fasteners hand tight.
9. Tighten the fill tube fastener at the bellhousing to 39 Nm (29 ft. lbs.). The bellhousing
(upper) fastener must be tightened first.
10. Tighten the lower fill tube fastener to 12 Nm (105 in. lbs.).
11. Did the original transmission oil fill tube seal leak when tested in Section A?
a. If YES >> Proceed to Section F - Fill And Mix the Transmission Oil Prior To Flush.
b. If NO >> STOP. No further repairs are required.
D. Torque Converter Replacement:
1. Remove the transmission oil pan and drain old oil. Temporarily install the transmission
oil pan.
2. Replace the transmission torque converter. Follow the detailed repair procedures on
TechCONNECT - SERVICE INFO tab / 21 - Transmission Transaxle / Automatic -
NAG1 / Torque Converter / Removal and Installation.
NOTE: During transmission installation, do not install the 13-way electrical harness
connector to the transmission, do not install the transmission oil fill tube,
and do not add new transmission fluid to the transmission.
NOTE: Immediately prior to transmission installation, it will be important to check
the converter seating with a scale and straightedge to prevent damage to the
torque converter or oil pump. Surface of converter lugs should be at least 19
mm (3/4 in.) to rear of straightedge when converter is fully seated.
NOTE: To not contaminate the new torque converter with the old transmission oil.
DO NOT start vehicle or add transmission oil to the transmission at this time.
In the following sections, the old transmission oil must be drained entirely
from the transmission and oil cooler. The old transmission filter and oil fill
tube seal must be replaced. Once this is completed, a flush and fill of the
transmission oil must be performed six ( 6 ) times for vehicles that have had
a torque converter replaced.
3. Proceed to Section E - Transmission Oil Drain.
E. Transmission Oil Drain:
1. Place a suitable drain pan under the transmission oil pan.
2. Remove the transmission oil pan. The oil pan seal is reusable.
3. Remove and discard the old transmission oil filter.
4. If not already performed, disconnect the 13-way wiring connector to the transmission
by turning the bayonet lock counterclockwise.
5. Loosen the transmission 13-way connector guide bushing screw located in the center
of the transmission side of the 13-way connector and remove the connector guide
bushing. Discard the two O-rings on the guide bushing.
NOTE: The 13-way connector guide bushing must be removed prior to the removal
of the valve body or damage to the valve body electrical lead frame may
occur. Also, replace the two guide bushing O-rings during reassembly.
6. Loosen all of the valve body retaining bolts and allow the oil that was trapped behind
the valve body to drain.
21-003-06 -8-
7. Remove all of the transmission valve body retaining bolts and remove the valve body
from the transmission.
8. If not already removed, remove the transmission oil fill tube and oil fill tube seal.
9. Allow the old transmission oil to drain from the transmission.
10. Drain the valve body by rotating the valve body at different angles to drain any
remaining oil trapped inside the valve body.
NOTE: Do not disassemble the valve body.
11. Using Mopar Brake Parts Cleaner, clean the outside surfaces of the valve body
assembly and the inside surface of the transmission oil pan.
12. Using shop air, blow off the valve body assembly and transmission oil pan.
13. Install the valve body to the transmission. Tighten the valve body retaining bolts to 8
Nm (70 in. lbs.).
14. Install new O-rings (2) to the 13-way connector guide bushing. Lightly lube O-rings
prior to installation.
15. Install the 13-way connector guide bushing to the transmission. Tighten the guide
bushing retaining screw to 1.5 Nm (22 in. lbs.).
16. Connect the 13-way wiring connector to the transmission by inserting the plug
connector into the guide bushing and turning the bayonet lock of the guide bushing
clockwise.
17. Install the new transmission oil filter.
18. Verify that both oil cooler line connections to the transmission are correct and tight.
Install the dust covers over each connections.
19. Install the transmission oil pan using the original oil pan gasket. Tighten the retaining
bolts to 8 Nm (70 in. lbs.).
20. Proceed to Section C - Fill Tube Oil Seal Replacement.
F. Fill And Mix The Transmission Oil Prior To Flush:
1. Lower the vehicle.
2. On vehicles that had the torque converter replaced, pour 7.5 liters (8 quarts) of new
ATF+4 transmission oil into the transmission through the fill tube.
3. On vehicles that DID NOT have the torque converter replaced, pour 4.75 liters (5
quarts) of new ATF+4 transmission oil into the transmission through the fill tube.
4. Mix the transmission oil before flushing the transmission fluid from the transmission.
a. Turn off the air conditioning.
b. With the parking brake engaged and the service brake pedal applied, start the
engine.
c. Allow the engine to idle for a moment.
d. With the brakes fully applied, place the transmission in “Reverse” and open the
throttle 25% for 10 seconds. Release the throttle.
e. Place the transmission in “Neutral” and hold the engine RPM's at 2,000 for 10
seconds.
f. With the brakes fully applied, place the transmission in “Drive” and open the throttle
25% for 10 seconds. Release the throttle.
g. Place the transmission in “Neutral” and hold the engine RPM's at 2,000 for 10
seconds.
h. With the brakes fully applied, place the transmission in “Reverse” and open the
throttle 25% for 10 seconds. Release the throttle.
i. Place the transmission in the “Park” position and turn off the engine.
5. Remove the front fascia from the vehicle. Protect fascia surface from damage (Fig. 5).
6. Remove the plastic push pin used to secure the top end of the black plastic deflector
shield. The shield is located in front of the transmission oil cooler line connectors.
-9- 21-003-06
7. Remove the transmission oil cooler the BOTTOM oil cooler line. The bottom line is the
oil return line back to the transmission.
NOTE: DO NOT disconnect the TOP cooler line from the transmission oil cooler.
8. Connect a 2 ft. (61 cm.) long 3/8” diameter hose to the open end of the bottom oil
cooler line. Temporarily secure the hose to the cooler line with a standard hose clamp.
9. Connect a 2 ft. (61 cm.) long 3/4” diameter hose to the open end of the oil cooler
bottom fitting. Temporarily secure the hose to the cooler line with a standard hose
clamp.
10. Route the hose ends into a suitable drain pan.
Fig. 5 DRAIN HOSES AT TRANS COOLER
1 - Combination Cooler - Transmission Oil Cooler and A/C Condenser
2 - Plastic Air Deflector
3 - Lower Oil Cooler Fitting - Use Lower Fitting To Flush Transmission And Oil Cooler
4 - Top Oil Cooler Fitting - DO NOT Disconnect Top Fitting and Line
5 - Lower (Return) Oil Cooler Line - Lower Line Returns Cooled Oil Back To Transmission
6 - 3/4” Diameter Rubber Drain Hose - Clamp Drain Hose To Lower Cooler Fitting
7 - 3/8” Diameter Rubber Drain Hose - Clamp Drain Hose To Lower Return Line
11. With the parking brake engaged and the service brake pedal applied, start the engine.
With the brakes fully applied, place the transmission into the “Drive” position. Allow the
transmission to pump out all of the transmission oil into the drain pan. Once all of the
transmission oil has been pumped out, place the transmission in to the “Park” position
and turn off the engine.
NOTE: The transmission oil is flushed by having the oil in the transmission pan
drawn through the transmission internals, through the outlet oil cooler line to
the oil cooler, through the oil cooler and into the drain hose and drain pan.
21-003-06 -10-
12. Install an additional 4.75 liters (5 quarts) of new ATF+4 transmission fluid into the
transmission through the fill tube.
13. Repeat steps 11 and 12 five (5) additional times to thoroughly flush the
transmission.
14. Disconnect the two drain hoses from the transmission oil cooler and bottom oil cooler
line.
15. Connect the bottom oil cooler line to the transmission oil cooler. Verify a positive
connection. Install the cooler line connection dust cover.
16. Position the deflector shield to the radiator support and install the plastic push pin.
17. Install the front fascia to the vehicle.
18. Proceed to Section G - Final Transmission Fluid Fill-Up and Check.
G. FINAL TRANSMISSION FLUID FILL-UP AND CHECK:
WARNING:Risk of accident from vehicle starting off by itself when engine running.
Risk of injury from contusions and burns if you insert your hands into
the engine when it is started or when it is running. Secure vehicle to
prevent it from moving off by itself. Wear properly fastened and
close-fitting work clothes. Do not touch hot or rotating parts.
CAUTION: Transmission oil temperature readings are taken using the StarSCAN®
tool. The transmission oil temperature can be read ONLY when the gear
selector and transmission are in either the Reverse “R” or in one of the
Drive “D” (forward gear) positions. Always set the vehicle park brake
AND apply the vehicle service brake when taking transmission oil
temperature readings. Take a transmission oil temperature reading and
return the transmission to the Park “P” position. When the vehicle is in
either Park “P” or Neutral “N” the StarSCAN® displays the ENGINE
coolant temperature (not the transmission oil temperature).
1. Monitor the transmission oil temperature:
a. Set the vehicle parking brake.
b. Connect the StarSCAN® to the vehicle diagnostic link connector.
c. Apply the vehicle service brake. Start the engine and let it run at idle speed with the
transmission selector in the Park "P" position.
d. With the service brake applied, shift through the transmission modes several times
with the vehicle stationary and the engine idling.
e. Return the transmission selector to the Park “P” position.
f. With the engine running, allow the transmission to warm up.
g. Apply the vehicle service brake, shift the transmission into Reverse “R” or Drive “D”
position, and monitor the transmission oil temperature using the StarSCAN®. Shift
the transmission back into the Park “P” position.
h. Continue to monitor the transmission oil temperature until the transmission oil
temperature is within the temperature range of the Transmission Fluid Graph (Fig.
6). Place the transmission selector in the Park “P” position.
NOTE: Always check the oil level while the engine is running and the transmission
selector is in the Park “P” position.
NOTE: For the LX/LE (300/Magnum/Charger), the handle end of special tool 9336
transmission oil dipstick may protrude from the fill tube when installed.
-11- 21-003-06
Fig. 6 NAG1 Transmission Fill Graph
2. On the LX/LE, remove the dipstick tube cap. Push the transmission oil dipstick
(Special Tool 9336) into the transmission fill tube until the dipstick tip contacts the oil
pan. Pull out the dipstick and read the transmission oil level. Repeat if necessary.
a. Check transmission oil temperature using the StarSCAN®.
b. The transmission Oil Dipstick 9336 has indicator marks every 10 mm. Determine
the height of the oil level on the dipstick. Using the height, the transmission
temperature, and the Transmission Fluid Graph (Fig. 6), determine if the
transmission oil level is correct.
c. Add or remove oil as necessary and recheck the oil level.
d. Once the oil level is correct, install the dipstick tube cap.
3. Proceed to Section H - Reset Transmission “Learned Adaptives” Using the
StarSCAN®.
H. Reset Transmission “Learned Adaptives” Using The StarSCAN®:
1. Allow the engine and transmission to warm to normal operating temperature.
2. Connect the StarSCAN® to the vehicle Data Link Connector (DLC).
3. Starting at the StarSCAN® home screen select “ECU view”.
4. Select “TCM EGS 52 Transmission”.
5. Select the “Data Display” screen.
6. Select “Reset Learned Adaptives”.
7. Press the blue “Start” button in the upper right corner of the StarSCAN® screen.
8. Press the blue “Next” button
9. Allow the StarSCAN® to reset the learned adaptives.
10. Press the “Finished” button and then remove the StarSCAN® from the vehicle.