transmission DODGE RAM SRT-10 2006 Service Repair Manual

FLUID
STANDARD PROCEDURE - FLUID DRAIN AND REFILL
The fill (2) and drain (3) 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 20-34 Nꞏm (15-25
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 20-34 Nꞏm (15-25 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 mayhave spilled onto the exhaust.
10. Lower vehicle.

A straight line shift pattern is used with a NEUTRAL detent. Lever range positions are imprinted in the shift knob.
SHIFTING
The transfer case can be shifted between the 2H and 4H operating ranges while the vehicle is in motion. The vehi-
cle must have the transmission placed in NEUTRAL, or the clutch depressed in the case of a manual transmission,
and be moving less than 2-3 MPH when shifting into and out of the 4L operatingrange.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV271
Before beginning repair on a suspected transfer case malfunction, check all other driveline components beforehand.
The actual cause of a problem may be related to such items as: front hubs, axles, propeller shafts, wheels and tires,
transmission, or clutch instead. If all other driveline components are ingood condition and operating properly, refer
to the Diagnosis Chart for further information.
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer Case difficult to shift or will
not shift into desired range.1) Vehicle speed too great to permit
shifting.1) Stop vehicle and shift into
desired range. Or, reduce speed to
below 3-4 km/h (2-3 mph) before
attempting the shift.
2) If vehicle was operated for an
extended period in 4H on a dry
paved surface, the driveline torque
load may be causing a bind.2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate
vehicle in 2H on dry paved
surfaces.
3) Transfer case external shift
linkage binding.3) Lubricate, repair, or replace
linkage bushings, or tighten loose
components as necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill to edge of fillhole
with Mopar
ATF +4, Automatic
Transmission fluid.
5) Internal components binding,
worn, or damaged.5) Disassemble the transfer case
and replace worn or damaged
components as necessary.
Transfer Case noisy in all operating
ranges.1) Insufficient or incorrect lubricant. 1) Drain and refill to edge of fillhole
with Mopar
ATF +4, Automatic
Transmission fluid.
Noisy in, or jumps out of, four wheel
drive low range.1) Transfer case not completely
engaged in 4L position.1) With the transmission in
NEUTRAL, or the clutch depressed
in the case of a manual
transmission and the vehicle moving
under 3-4 km/h (2-3 mph), shift the
transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair
linkage as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.4) Disassemble unit and repair as
necessary.
5) Low range gear worn or
damaged.5) Disassemble unit and repair as
necessary.

Condition Possible Cause Correction
Lubricant leaking from output shaft
seal or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Vent closed or restricted. 2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or
installed incorrectly.3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.1) Operate vehicle in the 2H
position on hard, dry surfaces.
REMOVAL
1. Raise and support vehicle.
2. Remove skid plate, if equipped. (Refer to 13 - FRAMES & BUMPERS/FRAME/TRANSFER CASE SKID PLATE
- REMOVAL)
3. Position drain oil container under transfer case.
4. Remove transfer case drain plug and drain lubricant into container.
5. Disconnect vent hose and transfer case position sensor connector.
6. Disconnect shift rod from grommet in transfer case shift lever, or from floor shift arm whichever provides easy
access. Use channel lock style pliers to press rod out of lever grommet.
7. Support transmission with jack stand.
8. Mark front and rear propeller shafts for assembly reference.
9. Remove front and rear propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - REMOVAL)
10. Support transfer case with suitable jack. Secure transfer case to jackwith safety chains.
11. Remove nuts attaching transfer case to transmission.
12. Move transfer case assembly rearward until free of transmission outputshaft.
13. Lower jack and move transfer case from under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubricant remaining in
case.

18. Install the rear output shaft bearing into the rear
case (1) using Seal Installer 8152 (3) and Univer-
sal Handle C-4171 (2).
19. Install the rear output shaft bearing snap-ring into
the rear case half.
INPUT AND PLANETARY GEAR
1. Lubricate gears and thrust washers with recom-
mended transmission fluid.
2. Install bottom thrust washer (2) in low range gear
planetary (1). Be sure washer tabs are properly
aligned in gear notches.

SHIFT FORKS AND MAINSHAFT
1. Lubricate mainshaft splines with recommended
transmission fluid.
2. Coat the interior of the drive sprocket hub with
ATF+4 and install the drive sprocket drive hub (2)
onto the mainshaft (1).
3. Install the mode hub (2) onto the mainshaft (1).

4. Install the mode hub retaining ring (3) onto the
mainshaft (1).
5. Install the clutch gear (2) onto the output shaft (1).
Verify that the pointed ends of the clutch gear teeth
are pointing to the front of the mainshaft.
6. Lubricate sector shaft with transmission fluid and
install shift sector (1) in case. Position slot in sector
so it will be aligned with shift fork pin when shift
forks are installed.
7. Apply Loctite™ 242, or equivalent, to the threads of
the sector support to replenish the factory applied
patch. Install the shift sector support. Tighten the
sector support with Socket 9033 to 27-34 Nꞏm
(20-25 ft.lbs.).

6. Install the extension housing boot and seal assem-
bly with Seal Installer 9037 (3) and Universal Han-
dle 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. Align and seat transfer case on transmission. Be sure transfer case input gear splines are aligned with trans-
mission output shaft. Align splines by rotating transfer case rear outputshaft yoke if necessary. Do not install any
transfer case attaching nuts until the transfer case is completely seatedagainst the transmission.
2. Install and tighten transfer case attaching nuts. Tighten nuts to 30-41Nꞏm (20-30 ft.lbs.).
3. Remove jack stand from under transmission.
4. Align and connect propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPEL-
LER SHAFT - INSTALLATION)
5. Connect vent hose and transfer case position sensor connector.
6. Connect shift rod to transfer case lever or floor shift arm. Use channel lock style pliers to press rod back into
lever grommet.
7. Adjust shift linkage, if necessary.
8. Fill transfer case with recommended transmission fluid and install fillplug.

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.

TRANSFER CASE - NV243 - SERVICE INFORMATION
DESCRIPTION
The NV243 is an electronically controlled part-time transfer case with a low range gear reduction system. The
NV243 has three operating ranges plus a NEUTRAL position. The low range system provides a gear reduction ratio
for increased low speed torque capability.
The geartrain is mounted in two aluminum case halves attached with bolts. The mainshaft front and rear bearings
are mounted in aluminum retainer housings bolted to the case halves.
OPERATING RANGES
Transfer case operating ranges are:
2WD (2-wheel drive).
4HI (4-wheel drive).
4LO (4-wheel drive low range).
NEUTRAL.
The 2WD range is for use on any road surface at any time.
The 4HI and 4LO ranges are for off road use only. They are not for use on hard surface roads. The only exception
being when the road surface is wet or slippery or covered by ice and snow.
The low range reduction gear system is operative in 4LO range only. This range is for extra pulling power in off road
situations. Low range reduction ratio is 2.72:1.
SHIFT MECHANISM
Operating ranges are selected with a dash mounted shift selector switch. The shift selector switch provides a input
to the Transfer Case Control Module (TCCM) to indicate the driver’s desireto change operating ranges. The TCCM
uses this input, along with input from the transfer case mounted mode sensor and information from the vehicle’s
bus, to determine if a shift is permitted. If the TCCM decides the shift is permitted, the TCCM controls the shift
motor, mounted to the exterior of the transfer case, to perform the shift.
IDENTIFICATION
A circular ID tag (1) is attached to the rear case of
each transfer case. The ID tag provides the transfer
case model number, assembly number, serial number,
and low range ratio.
The transfer case serial number also represents the
date of build.
OPERATION
The input gear is splined to the transmission output shaft. The input gear drives the mainshaft through the planetary
assembly and range sleeve. The front output shaft is operated by a drive chain that connects the shaft to a drive
sprocket on the mainshaft. The drive sprocket is engaged/disengaged by themodefork,whichoperatesthemode
sleeve and hub. The sleeve and hub are not equipped with a synchronizer mechanism for shifting.

DIAGNOSIS AND TESTING - TRANSFER CASE - NV243
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer case difficult to shift or will
not shift into desired range.1) Transfer case electronically
controlled shift system malfunction.1) Verify proper operation per the
appropriate diagnostic manual.
2) If vehicle was operated for an
extended period in 4HI mode on dry
surface, driveline torque load may
cause difficulty.2) Drive the vehicle in a straight line
and momentarily release the
accelerator. The transfer case can
then be shifted to the desired mode.
3) Insufficient or incorrect lubricant. 3) Drain and refill transfer casewith
the correct quantity of Mopar
AT F
+4, Automatic Transmission Fluid.
4) Internal transfer case
components binding, worn, or
damaged.4) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.1) Insufficient or incorrect lubricant. 1) Drain and refill transfer casewith
the correct quantity of Mopar
AT F
+4, type 9602, Automatic
Transmission Fluid.
2) Internal transfer case
components binding, worn, or
damaged.2) Repair or replace components as
necessary.
Transfer case noisy while in, or
jumps out of, 4LO mode.1) Transfer case not completely
engaged in 4LO position.1) While rolling 2-3 MPH and the
transmission in NEUTRAL, or clutch
depressed on vehicles equipped
with a manual transmission, shift
transfer case to the 2WD or 4HI
position, and then back into the 4LO
position.
2) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.2) Repair or replace components as
necessary.
3) Low range gear worn or
damaged.3) Repair or replace components as
necessary.
Lubricant leaking from transfer case
seals or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.3) Replace suspect seal.
Abnormal tire wear. 1) Extended operation in 4HI mode
on dry surfaces,1) Operate vehicle in 2WD mode on
dry surfaces.