DODGE RAM SRT-10 2006 Service Repair Manual

6. Install the extension housing dust boot and seal
assembly with Seal Installer 9037 (3) and Universal
Handle C-4171 (2).
7. Install the front companion flange onto the front
output shaft.
8. Install two bolts 180° apart into the front output
shaft companion flange.
9. Place holder (1) over the bolts (2) and against the
companion flange.
10. Install a new front companion flange nut. Tighten
the companion flange nut to 176-271 Nꞏm
(130-200 ft.lbs.).
INSTALLATION
1. Mount transfer case on a transmission jack.
2. Secure transfer case to jack with chains.
3. Position transfer case under vehicle.
4. Align transfer case and transmission shafts and install transfer case onto the transmission.
5. Install and tighten transfer case attaching nuts to 27-34 Nꞏm (20-25 ft.lbs.) torque.
6. Connect the vent hose.
7. Connect the shift motor and mode sensor wiring connectors. Secure wire harness to clips on transfer case.
8. Align and connect the propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/FRONT
PROPELLER SHAFT - INSTALLATION) (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/REAR
PROPELLER SHAFT - INSTALLATION)
9. Fill transfer case with correct fluid. (Refer to 21 - TRANSMISSION/TRANSFER CASE/FLUID - STANDARD PRO-
CEDURE)
10. Install skid plate, if equipped.

11. Remove transmission jack and support stand.
12. Lower vehicle and verify transfer case shift operation.
SPECIFICATIONS
TRANSFER CASE - NV273
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Extension Housing 27-34 20-25 -
Bolt, Case Half 27-34 20-25 -
Support, Sector 27-34 20-25 -
Nuts, Mounting 30-41 20-30 -
Bolts, Shift Motor and
Mode Sensor Assembly16-25 12-18 -
Nut, Companion Flange 176-271 130-200 -

SPECIAL TOOLS
TRANSFER CASE NV271/NV273
Handle, Universal - C-4171
Remover - L-4454
Installer, Bearing - 6953
Installer, Pump Housing Seal - 7888
Installer, Bearing - 8128
Cup - 8148
Installer - 8151
Installer - 8152
Installer - 8891

Socket - 9033
Installer, Bearing - 9035
Installer, Seal - 9036
Installer, Seal - 9037

BOOT-EXTENSION HOUSING SEAL AND DUST
REMOVAL
1. Raise and support vehicle.
2. Remove rear propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - REMOVAL)
3. Use a suitable chisel or pry tool to remove the rear
extension housing dust boot (2).
4. Use a suitable chisel or pry tool to remove the rear
extension housing seal.
INSTALLATION
1. Clean fluid residue from sealing surface and
inspect for defects.
2. Install the extension housing dust boot and seal
assembly with Seal Installer 9037 (3) and Universal
Handle C-4171 (2).
3. Install propeller shaft. (Refer to 3 - DIFFERENTIAL
& DRIVELINE/PROPELLER SHAFT/PROPELLER
SHAFT - INSTALLATION)
4. Verify proper transfer case fluid level.
5. Lower vehicle.

FLUID
STANDARD PROCEDURE - FLUID DRAIN AND REFILL
The fill (1) and drain (2) plugs are both in the rear
case.
1. Raise vehicle.
2. Position drain pan under transfer case.
NOTE: It may be necessary to remove the exhaust
y-pipe at the exhaust manifold to properly access
the fill and drain plugs. Lowering the exhaust will
allow the plugs to be accessed for torquing during
installation. (Refer to 11 - EXHAUST SYSTEM/EX-
HAUST PIPE - REMOVAL)
3. Remove drain and fill plugs and drain lubricant
completely.
4. Install drain plug. Tighten plug to 41-54 Nꞏm (30-40
ft. lbs.).
5. Remove drain pan.
6. Fill transfer case to bottom edge of fill plug opening
with Mopar
ATF +4, Automatic Transmission fluid.
7. Install and tighten fill plug to 41-54 Nꞏm (30-40 ft. lbs.).
8. Install the exhaust y-pipe to the exhaust manifold, if removed. (Refer to 11 - EXHAUST SYSTEM/EXHAUST
PIPE - INSTALLATION)
9. Wipe any excess fluid that may have spilled onto the exhaust.
10. Lower vehicle.

SEAL-FRONT OUTPUT SHAFT
REMOVAL
1. Remove the front propeller shaft (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL).
2. Install two bolts 180° apart into the front output
shaft companion flange.
3. Place Yoke Holder 6719 (1) over the bolts (2) and
against the companion flange.
4. Remove and discard the front companion flange
nut.
5. Remove the companion flange from the front out-
put shaft. It may be necessary to use Pinion
Flange Remover 8992 to remove the companion
flange.
6. Using a screw and a slide hammer, remove the
front output shaft seal.
INSTALLATION
1. Install the new front output shaft seal with Seal
Installer MB991168A.
2. Install the front companion flange onto the front
output shaft.
3. Install two bolts 180° apart into the front output
shaft companion flange.
4. Place Yoke Holder 6719 (1) over the bolts (2) and
against the companion flange.
5. Install a new front companion flange nut. Tighten
the companion flange nut to 258-312 Nꞏm (190-230
ft.lbs.).
6. Install front propeller shaft (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION).

SENSOR-MODE
DESCRIPTION
The transfer case mode sensor (1) is an electronic
device whose output can be interpreted to indicate the
shift motor shaft’s rotary position. The sensor consists
of a magnetic ring and four Hall Effect Transistors to
create a 4 channel digital device (non-contacting)
whose output converts the motor shaft position into a
coded signal. The TCCM must supply 5VDC (+/- 0.5v)
to the sensor and monitor the shift motor position. The
four channels are denoted A, B, C, and D. The sensor
is mechanically linked to the shaft of the cam which
causes the transfer case shifting. The mode sensor
draws less than 53 mA.
OPERATION
During normal vehicle operation, the Transfer Case Control Module (TCCM)monitors the mode sensor outputs at
least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor
is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined.
Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector
versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the
sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears posi-
tions can also be referred as the transfer case’s coarse position. These coarse positions come into play during shift
attempts.
SECTOR ANGLES vs. TRANSFER CASE POSITION
Shaft Angle (Degrees) Transfer Case Position
+40 4LO
+20 N
0 2WD/AWD
-20 4HI
MODE SENSOR CHANNEL STATES
Transfer Case
Angle (degrees)Sensor Channel A Sensor Channel B Sensor Channel C Sensor Channel D
Between Gears H H L H
+40 (4LO) H H L L
Between Gears H H L H
Between Gears H L L H
+20 (NEUTRAL) H L L L
Between Gears H L L H
Between Gears H L H H

Transfer Case
Angle (degrees)Sensor Channel A Sensor Channel B Sensor Channel C Sensor Channel D
0 (2WD/AWD) H L H L
Between Gears H L H H
Between Gears L L H H
-20 (4HI) L L H L
Between Gears L L H H
Between Gears L H H H

SWITCH-SELECTOR
DESCRIPTION
The selector switch assembly is mounted in the left
side of the vehicle’s Instrument Panel (IP) and con-
sists of a rotary knob connected to a resistive network
for the mode and range shift selections. Also located
in this assembly is a recessed, normally open momen-
tary switch for making shifts into and out of transfer
case NEUTRAL. A pen, or similar instrument, is used
to make a NEUTRAL shift selection, thus reducing the
likelihood of an inadvertent shift request.
The selector switch also contains four light emitting
diode’s (LED’s) to indicate the transfer case position
and whether a shift is in progress.
OPERATION
As the position of the selector switchvaries, the resistance between the Mode Sensor supply voltage pin and the
Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module
(TCCM) are provided that interpret the selector switch resistance as giveninthetablebelow:SELECTORSWITCH
INTERPRETATION
SELECTOR SWITCH INTERPRETATION
Step Resistance Range (ohms) Required Interpretation
A <200 Shorted
B 400-700 NEUTRAL
C 1050-1450 4LO
D 1850-2300 4HI
E 3050-5950 2WD (Default)
F 9.5-12.5K In between positions
G>15.5KOpen
For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the
TCCM may interpret the resistance as:
either of the neighboring valid positions.
as an invalid fault position.
For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the
resistance as:
the 2WD position.
an invalid fault position.
a valid in-between position.
For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM
may interpret the resistance as:
a valid in-between position.
an invalid fault position.