Novak Conversions Jeep Wrangler TJ engine mounts

Wrangler TJ Technical Service Bulletins (TSBs)

SSTJ

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I'm going through TSBs, and will populate the tables below as I go along. (For an intro to TSBs, see here.)

If you have one you'd like to include, just post a reply and I'll add it.



FSM Section 2: Suspension

TSB_Number
Date_Published
Summary
Links
22-01-97Jun. 13, 1997Discussion and definition of "radial runout" and "lateral runout", and specified measurements.PDF
02-12-99Aug. 20, 1999This bulletin involves installing offset ball joints to allow adjustments to camber that were not previously possible on XJ, TJ, and ZJ models, and to camber and caster on WJ models.PDF



FSM Section 3: Differential and Drivetrain

TSB_Number
Date_Published
Summary
Links
05-02-98Mar. 13, 1998Part numbers for broken retaining clips for clutch packs. If the broken retaining clips have not damaged the gears or clutch packs in the Trac-Lok, order the following as it applies.PDF
03-001-05Jan. 13, 2005Off-roading in 4WD low range: axle lockers may unlock when ignition key is cycled. This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software.PDF
Note



FSM Section 5: Brakes

TSB_Number
Date_Published
Summary
Links
05-09-96Oct. 4, 1996This bulletin is designed to give you an understanding of the materials used in Chrysler brake systems. It will also familiarize you with some normal noises that may occur with a properly operating system.PDF
05-02-98Mar. 13, 1998A single click can be heard when the driver applies the brakes while traveling forward. Normally occurs the first time brakes are applied while moving forward, following a brake application in reverse.PDF
05-03-98Aug. 28, 1998The vehicle may exhibit minor brake pedal pulsation which may be caused by rough disc rotors. This condition will usually occur in warm climate, high humidity areas. (Originally FSM Section 2.)PDF



FSM Section 7: Cooling

TSB_Number
Date_Published
Summary
Links
07-03-97May 9, 1997Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals.PDF



FSM Section 8: Electrical

TSB_Number
Date_Published
Summary
Links
08-06-96Feb. 16, 1996Ignition Off Draw (IOD) circuits reduce current draw on batteries during shipment and storage. The illustration below ( See Illustration) shows the fuse operational location (Fuse No. 17).PDF
08-20-96Jul. 19, 1996Vehicles equipped with an AM/FM/Cassette (RAS) radio may enter the cassette play mode (without a cassette being inserted) before or during vehicle Road Ready.PDF
08-21-96Oct. 18, 1996Wiring Harness Connector Repair. Poor electrical connections and can be difficult to diagnose. These drivetrain electrical connector repair components aid with drivetrain electrical repairs.PDF
08-01-97Feb. 03, 1997The following JTEC PCM electrical connector and terminal repair components are available for repairing individual circuits without the need to replace the entire engine harness.PDF
08-09-97Feb. 28, 1997Every new vehicle built for the U.S. market on or after Feb. 25, 1997 is required by Federal Law to have new Air Bag Warning Labels applied to the visor(s) and glove box as determined by vehicle line.PDF
Note
Recall 712Apr. 01, 1997Customer notification re airbag safety. The enclosed owner notification letters advise owners of the above vehicles of the steps that can be taken to minimize the risk of harm from a deploying air bag.PDF
Recall 731Jul. 01, 1997The airbags on the above listed vehicles may inadvertently deploy during a three (3) second period after ignition key has been turned to off position, which could injure occupant. Airbag control module must be replaced.PDF
08-24-97Jul. 11, 1997The odometer display may flash when the emergency flashers are activated. This could be due to a incorrectly wired park & turn signal lamp socket.PDF
08-32-97
08-99-98
08-37-99
Sep. 19, 1997
Jan. 20, 1999
Nov. 12, 1999
These bulletins identify the parts and procedures necessary to deactivate airbags authorized by NHTSA. The second/middle entry applies only to Canadian vehicles.PDF
PDF
PDF
08-07-99Mar. 12, 1999A repair kit has been released for repairing the PDC when internal damage has occurred. This will eliminate the need to replace the entire engine compartment wire harness,PDF
08-23-99Jul. 9, 1999Attached is a copy of DaimlerChryslers Radio Communication Equipment Installation Recommendations, to assist in properly installing communication equipment.PDF
18-08-00June 23, 2000Erroneous MIL illumination due to DTC P0107 (Map sensor voltage too low). This may occur during downhill decelerations at altitude or when performing off-road maneuvers when the engine is operating over 1500 rpm.PDF
08–27–00Sep. 29, 2000Non-Deployed Airbag Handling Procedures. All damaged or faulty and non-deployed driver, passenger, or side airbag(s) or partially de- ployed 2001 JA and RS front airbags fall into one of two categories.PDF
08-006-00Dec. 29, 2000This bulletin provides a revised wire splice procedure and related parts. This is the only procedure approved by Daimler Chrysler Engineering.PDF
25-003-01Feb. 23, 2001Erroneous DTC P1398 (or $BA) - No Crank Sensor Learn: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 96Cal18 or 97Cal18).PDF
08-010-01May 25, 2001Airbag/Clock Spring Service: When servicing any airbag system, follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing any component.PDF
08-025-01Nov. 23, 2001Airbag On-Off Switches: DaimlerChrysler is now offering airbag on-off switches for selected vehicles listed. The switches are packaged in a kit containing all necessary parts and detailed instruction sheet.PDF
18-037-05Oct. 20, 2005Flash Programming Failure Recovery Using DRBIII: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts.PDF



FSM Section 9: Engine

TSB_NumberDate_Published
Summary
Links
09-010-04Oct. 01, 20044.0L Engine - Dirt And Debris Accumulation At Rear Main Seal. This bulletin involves the application of a small amount of sealer where the top of the transmission bellhousing mates to the engine.PDF



FSM Section 11: Exhaust

TSB_NumberDate_Published
Summary
Links
11-07-98Dec. 11, 1998Outer Exhaust Manifold Studs Breaking. This document provides new torque specs. See also the images here. Note: Applies to vehicles equipped with 2.5L engine and built prior to December 7, 1998.PDF
Recall E22Aug. 01, 2006The PCM may not detect a deteriorating catalytic converter. Also, some catalytic converters may be subject to mechanical degradation and rattle. Note: For TJs, applies only to 2.5L (EPE) engine.PDF



FSM Section 14: Fuel System

TSB_Number
Date_Published
Summary
Links
18-03-96Apr. 19, 1996The following is a list of PCM updates for erroneous MIL (Check Engine Lamp) illumination and/or driveability concerns. Please perform updates to the PCM for any vehicle listed above that you encounter.PDF
14-03-97May 30, 1997The fuel gauge needle may not reach the full mark with a full tank of fuel. If the symptom is present, perform the Repair Procedure.PDF
14-05-97Jun. 27, 1997The fuel tank may be slow to fill. The gasoline pump may repeatedly shut off while filling. A fuel tank with an improved venting system has been released which will improve this condition.PDF
14-06-97Jul. 3, 1997Symptoms may include no start, rough idle, long crank times, driveway die outs or erratic fuel pressure. A new fuel pump has been released which delivers improved performance.PDF
08-19-97Jul. 25, 1997The fuel gauge may not read accurately. The vehicle may run out of fuel with the gauge reading 1/4 to 1/8 tank. A separate sending unit has been released.PDF
14-08-97Nov. 21, 1997Poor driveability with high DI (Driveability Index) fuel. Long cold start times, warm-up sags, hesitations, and driveway die outs. Symptoms are most noticeable at moderate ambient temperatures.PDF
Recall 755Jun. 01, 1998The fuel tank level sending unit on about 400,000 vehicles may cause the vehicle to run out of fuel when the fuel gauge still indicates that there is fuel remaining in the tank. Unit must be replaced.PDF
18-12-99Jun. 18, 1999Explains LDP - Monitor Test. Original test functionality was eliminated in DRB III. A new test has been incorporated into the PCM. NOTE: This bulletin supersedes technical service bulletin 18-17-97, dated May 2, 1997.PDF
18-01-00Feb. 04, 2000During evaporative system diagnosis, Leak Detection Pumps have mistakenly been replaced. A thorough inspection for pinched, kinked, or disconnected supply vacuum lines is a critical step.PDF



FSM Section 18: Vehicle Performance (PCM)

TSB_Number
Date_Published
Summary
Links
18-03-96Apr. 19, 1996Erroneous MIL illumination / driveability improvements. Note: Applies only to Wranglers built before July 15, 1996. Such vehicles can be recognized by an eight-digit part number on the PCM, rather than ten digits.PDF
18-26-96Sep. 27, 1996Erroneous MIL illumination / driveability Improvements. Note: Applies only to Wranglers built after July 15, 1996. Such vehicles can be recognized by a ten-digit part number on the PCM, rather than eight digits.PDF
18-31-96Nov. 8, 1996MIL light may show Diagnostic Trouble Code 77 (fuel system lean) when diagnostics are performed. The vehicle may exhibit a cold engine idle shake, sag or hesitation with or without the code. Note: Applies only to 2.5L engine.PDF
18-32-96Nov. 8, 1996Erroneous MIL illumination / driveability improvements. Note: Applies only to Wranglers built before July 15, 1996. Such vehicles can be recognized by an eight-digit part number on the PCM, rather than ten digits.PDF
18-12-97Mar. 14, 1997Erroneous MIL illumination / driveability Improvements. Note: Applies only to Wranglers built after July 15, 1996. Such vehicles can be recognized by a ten-digit part number on the PCM, rather than eight digits.PDF
18-21-98Jun. 5, 1998Powertrain Control Module (PCM) Service Caution: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal.PDF
18-12-99Jun. 18, 1999This bulletin explains the operation and application of the LDP: Monitor Test. The original test (LDP Dealer Test Mode) functionality was eliminated in the DRB III®. Note: This TSB supersedes 18-17-97.PDF
18-01-00Feb. 4, 2000Misdiagnosed leak detection pump systems with the following DTCs: P1494, P0442, P0455, or P0456. Note: This TSB applies only to 1997–2000 TJ models.PDF
PDF
18-08-00Jun. 23, 2000Erroneous MIL DTC P0107 (map sensor voltage too low). Involves erasing and reprogramming the JTEC PCM with new software (calibration change 96Cal18, 97Cal18 and 98Cal12). Note: Applies only to 1997–1998 TJ models.PDF
PDF
21-04-00Jun. 30, 2000Erroneous MIL P1763 (transmission governor pressure sensor volts too high). Involves selectively erasing and reprogramming the JTEC PCM (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14).PDF
18-012-01May 25, 2001Generic Scan Tool (GST). Information Only.PDF
18-029-05Jun. 30, 2005Co-Pilot support and correct cable usage. Dealership technician has a choice when recording data from a supported Powertrain Control Module (PCM) or Transmission Control Module (TCM).PDF
18-037-05Oct. 20, 2005Flash programming failure recovery using DRB III. This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts.PDF



FSM Section 19: Steering

TSB_Number
Date_Published
Summary
Links
19-03-96Jun. 28, 1996Power steering fluid may seep from the bottom of the power steering fluid reservoir. Inspect the reservoir. If fluid seepage is present perform the Repair Procedure.PDF
09-09-96Sep. 13, 1996MIL light may illuminate indicating DTG code $73 - SAE Trouble Code P0551, power steering switch failure. NOTE: Applies to vehicles with 2.5L engines.PDF
Recall 773Apr. 01, 1998The steering column "clockspring" on about 1,600 vehicles may break when the steering wheel is fully turned. This deactivates the drivers airbag, and then the clockspring must be replaced.PDF



FSM Section 21: Transmission and Transfer Case

TSB_Number
Date_Published
Summary
Links
21-006-05Feb. 24, 2005NSG370 6-Spd Transmission - May Not Remain In Reverse Gear When Selected. This bulletin involves replacing both the internal shift subassembly and the mainshaft reverse gear components.PDF



FSM Section 23: Body

TSB_Number
Date_Published
Summary
Links
23-09-98Mar. 13, 1998A rattling or knocking noise may be present when driving over rough roads. The noise is a solid knocking noise, coming from the rear of the vehicle that can be confused with shock absorber noise.PDF



FSM Section 25: Emissions

TSB_Number
Date_Published
Summary
Links
25-001-07Feb. 09, 2007I/M "Readiness Check" continues to indicate that OBD system is not ready for I/M testing. Note: This bulletin involves modifying wiring in the Power Distribution Center (PDC).PDF
Note
25-005-13Sep. 14, 2013I/M "Readiness Check" continues to indicate that OBD system is not ready for I/M testing. Note: This bulletin is an updated version of 25-001-07 (above).PDF
Note


FSM Section N/A: LOL

TSB_Number
Date_Published
Summary
Links
14-03-96May 10, 1996The fuel filler bezel screws may rust prematurely. Inspect the screws. If the screws appear rusty, replace.PDF
08-36-98Jul. 24, 1998There has been a great deal of recent media attention regarding the turn of the century (year 2000, Y2k, etc.) and the effect it will have on computers that use two digit calender year coding.PDF
08-11-00March 24, 2000Some recordable compact disc media, such as CD-R and CD-RW, may not comply with the standard CD format used in automotive CD players.PDF
 
Last edited:
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This post will host all of the PDFs, which will also be linked in the tables in the original post.

UPDATE: There is a 40-file limit per post. Second set of files is here.


 

Attachments

Last edited:
@Chris

Hi Chris. If you agree, I suppose this should probably be moved to the Resource section.
 
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Also tagging @Wildman, who I think first educated me on TSBs.

Working in the industry you learn about TSB's real fast. I've got TSB's on the Dodge Magnum V-8 that I try to share with folks who've done a V-8 swap. They can really help you fix issues at times.
 
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Working in the industry you learn about TSB's real fast. I've got TSB's on the Dodge Magnum V-8 that I try to share with folks who've done a V-8 swap. They can really help you fix issues at times.

Share them whenever you can. I'll add a section on TSBs for other relevant engines, etc.
 
Update: I'm done with the smaller categories. If anyone has others to add to those categories, let me know.

Next up is electrical, which has at least 15.
 
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This post will host all of the PDFs, which will also be linked in the tables in the original post.



Apparently there is a 40-file limit per post. Here's the second set, all linked in the original post of course.
 

Attachments

I just noticed that the TSBs (there are at least two of them that are very similar) for the 2005-2006 Wranglers failing emissions tests due to the I/M Readiness Check not being ready for testing is missing from your list. I've attached the two of them that I have run across here on the forum. In addition, here's how I'd recommend noting it in the initial post above:

FSM Section 25: Emissions Control

TSB_NumberDate_PublishedSummaryLinks
25-001-07Feb. 9, 2007This bulletin covers a wiring modification in the PDC that is necessary to correct an issue where the
vehicle On Board Diagnostics (OBD) system will not indicate readiness for I/M emissions
testing. The Catalyst Monitor, Oxygen Sensor Monitor, and Oxygen Sensor Heater Monitors may
indicate "Not Ready" even if the monitor is operating correctly and determining pass/fail
results.
25-005-13 Rev. ASept. 14, 2013An updated version of TSB 25-001-07 (see above).

Additionally, I've spent some time figuring out why this modification is required and what it does by reading the TSBs above, along with the Factory Service Manual, the Powertrain Diagnostic Procedures Manual, and a couple Chrysler technician course manuals on the NGC PCM (all available on this forum, by the way). It's a theory that I can't prove, so I don't know if you want to add it in the Summary or not (it's lengthy, but helpful to understand the "why" of the TSB modification). Here is my theory:

One side of the Automatic Shutdown (ASD) relay coil is sent +12V by the ignition switch when it's in the Run or Start positions, and the other side of the ASD relay coil goes to ground, but it's controlled (switched) by the PCM. The other switched contacts (which change state - open to closed - when the coil is energized) in the ASD relay are connected to Fuse #9 in the PDC (which is connected directly to battery positive) on the input side, and to an input in the PCM on the output side. When the ignition key is moved to the Run position (and Start, during start-up), the ignition switch connects one side of the ASD relay coil to +12V and the PCM "wakes up" and connects the other side of the ASD relay coil to ground, which energizes the ASD relay coil.

Once the ASD relay coil is energized, the contact inside the relay supplies input power to the ignition coil, fuel injectors, and the two upstream O2 sensor heaters, as well as sending a 12V input to the PCM so that it knows that the ASD relay changed state (closed). If the PCM doesn't sense an adequate signal from the crankshaft and camshaft position sensors within 1.8 seconds of receiving the 12V input from the ASD relay, it opens the ground to the ASD relay coil to de-energize the ignition coil, fuel injectors, and two of the O2 sensor heaters because it assumes the engine didn't start. The PCM also does this when the ignition is cut off, which shuts the engine down.

The two downstream oxygen sensor heaters are powered by a separate Oxygen Sensor Heater relay which is controlled by the PCM and delays power for about 2 seconds at start-up. The delay is necessary because four heaters starting simultaneously is too much current draw (especially with the large inductive in-rush current). The O2 Sensor Heater Monitor is continuously run, as long as the heaters are energized. The monitor is looking for a current drop in the heater circuit, which indicates heater failure. During PCM power down, the pass status of the O2 Sensor Heater Monitor is processed by the PCM.

The TCB change is simply to move the +12V supplied to the Automatic Shutdown (ASD) relay coil from ignition power (only on in Run or Start positions) to always hot (from Fuse 9, which is direct from the battery +, in the PDC). This modification is necessary because the PCM processes the O2 Sensor Heater Monitor result after the ignition is shut off ("shut-down housekeeping"). As wired from the factory, the two upstream O2 sensor heaters get power from the ignition switch via the ASD relay output, so as soon as you turn the key off, they lose power, unlike the two downstream O2 sensor heaters, which get power directly from the battery through Fuse #9. Since the status of the O2 Sensor Heater Monitor is processed at PCM power-down, which occurs after the ignition power is cut, the O2 Sensor Heater Monitor will always be in a not ready status when processed because the heater power has been cut by the ignition at the time the monitor is processed, so it thinks there was a heater failure right after shutdown, but before the Monitor is processed. I think it doesn't result in a sensor heater DTC because it takes two successive failures to trigger a DTC for a bad O2 sensor. Upon the next start-up, the PCM senses all heaters are working, and the failure counter is reset. In other words, each time you shut down, the failure counter goes from 0 to 1 when power is cut to the heaters, and then when you re-start, it goes from 1 to 0 when the heaters power up properly.

There have been reports of this modification fixing several "Readiness Monitor Not Ready" situations - not just the O2 Sensor Heater Monitor. I've found generic references in ODB2 standards that some other monitors won't run if there are any pending or permanent DTCs set in the PCM. I think that explains those unique situations. The bottom line is if you are getting the O2 Sensor Heater Monitor not ready error, check for this TSB modification, first. If it has not been done, perform it, and test again after driving your TJ.
 

Attachments

I just noticed that the TSBs (there are at least two of them that are very similar) for the 2005-2006 Wranglers failing emissions tests due to the I/M Readiness Check not being ready for testing is missing from your list. I've attached the two of them that I have run across here on the forum. In addition, here's how I'd recommend noting it in the initial post above:

FSM Section 25: Emissions Control

TSB_NumberDate_PublishedSummaryLinks
25-001-07Feb. 9, 2007This bulletin covers a wiring modification in the PDC that is necessary to correct an issue where the
vehicle On Board Diagnostics (OBD) system will not indicate readiness for I/M emissions
testing. The Catalyst Monitor, Oxygen Sensor Monitor, and Oxygen Sensor Heater Monitors may
indicate "Not Ready" even if the monitor is operating correctly and determining pass/fail
results.
25-005-13 Rev. ASept. 14, 2013An updated version of TSB 25-001-07 (see above).

Additionally, I've spent some time figuring out why this modification is required and what it does by reading the TSBs above, along with the Factory Service Manual, the Powertrain Diagnostic Procedures Manual, and a couple Chrysler technician course manuals on the NGC PCM (all available on this forum, by the way). It's a theory that I can't prove, so I don't know if you want to add it in the Summary or not (it's lengthy, but helpful to understand the "why" of the TSB modification). Here is my theory:

One side of the Automatic Shutdown (ASD) relay coil is sent +12V by the ignition switch when it's in the Run or Start positions, and the other side of the ASD relay coil goes to ground, but it's controlled (switched) by the PCM. The other switched contacts (which change state - open to closed - when the coil is energized) in the ASD relay are connected to Fuse #9 in the PDC (which is connected directly to battery positive) on the input side, and to an input in the PCM on the output side. When the ignition key is moved to the Run position (and Start, during start-up), the ignition switch connects one side of the ASD relay coil to +12V and the PCM "wakes up" and connects the other side of the ASD relay coil to ground, which energizes the ASD relay coil.

Once the ASD relay coil is energized, the contact inside the relay supplies input power to the ignition coil, fuel injectors, and the two upstream O2 sensor heaters, as well as sending a 12V input to the PCM so that it knows that the ASD relay changed state (closed). If the PCM doesn't sense an adequate signal from the crankshaft and camshaft position sensors within 1.8 seconds of receiving the 12V input from the ASD relay, it opens the ground to the ASD relay coil to de-energize the ignition coil, fuel injectors, and two of the O2 sensor heaters because it assumes the engine didn't start. The PCM also does this when the ignition is cut off, which shuts the engine down.

The two downstream oxygen sensor heaters are powered by a separate Oxygen Sensor Heater relay which is controlled by the PCM and delays power for about 2 seconds at start-up. The delay is necessary because four heaters starting simultaneously is too much current draw (especially with the large inductive in-rush current). The O2 Sensor Heater Monitor is continuously run, as long as the heaters are energized. The monitor is looking for a current drop in the heater circuit, which indicates heater failure. During PCM power down, the pass status of the O2 Sensor Heater Monitor is processed by the PCM.

The TCB change is simply to move the +12V supplied to the Automatic Shutdown (ASD) relay coil from ignition power (only on in Run or Start positions) to always hot (from Fuse 9, which is direct from the battery +, in the PDC). This modification is necessary because the PCM processes the O2 Sensor Heater Monitor result after the ignition is shut off ("shut-down housekeeping"). As wired from the factory, the two upstream O2 sensor heaters get power from the ignition switch via the ASD relay output, so as soon as you turn the key off, they lose power, unlike the two downstream O2 sensor heaters, which get power directly from the battery through Fuse #9. Since the status of the O2 Sensor Heater Monitor is processed at PCM power-down, which occurs after the ignition power is cut, the O2 Sensor Heater Monitor will always be in a not ready status when processed because the heater power has been cut by the ignition at the time the monitor is processed, so it thinks there was a heater failure right after shutdown, but before the Monitor is processed. I think it doesn't result in a sensor heater DTC because it takes two successive failures to trigger a DTC for a bad O2 sensor. Upon the next start-up, the PCM senses all heaters are working, and the failure counter is reset. In other words, each time you shut down, the failure counter goes from 0 to 1 when power is cut to the heaters, and then when you re-start, it goes from 1 to 0 when the heaters power up properly.

There have been reports of this modification fixing several "Readiness Monitor Not Ready" situations - not just the O2 Sensor Heater Monitor. I've found generic references in ODB2 standards that some other monitors won't run if there are any pending or permanent DTCs set in the PCM. I think that explains those unique situations. The bottom line is if you are getting the O2 Sensor Heater Monitor not ready error, check for this TSB modification, first. If it has not been done, perform it, and test again after driving your TJ.

Great, thank you. I have updated the list and added a link to both the PDFs and to your notes.
 
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My Google-fu is not turning up any kind of translation for what this TSB (3-001-05?) was that resulted in the need for a PCM update on my ‘05 TJR back in. 2009. Anybody have any insight?
This is the sticker under my hood. PO (original owner) had the update done

IMG_1563.jpeg
 
My Google-fu is not turning up any kind of translation for what this TSB (3-001-05?) was that resulted in the need for a PCM update on my ‘05 TJR back in. 2009. Anybody have any insight?
This is the sticker under my hood. PO (original owner) had the update done

View attachment 538321

It was a PCM flash to fix a problem where the lockers would disengage when you turned the key off. See attached. @SSTJ, please add this one to the list.
 

Attachments

Novak Conversions Jeep Wrangler TJ engine mounts