ECU DODGE RAM SRT-10 2006 Service Repair Manual

FRONT CASE AND REAR CASE
Inspect the cases for wear and damage.
Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces. Also
make sure the front case mounting studs are in good condition.
Check the front case mounting studs and vent tube. The tube can be secured with Loctite™ 271 or 680 if loose.
Thestudthreadscanbecleanedupwithadieifnecessary.Alsocheckcondition of the fill/drain plug threads in the
rear case. The threads can be repaired with a thread chaser or tap if necessary. Or the threads can be repaired with
Helicoil™ stainless steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the pump if any part appears to beworn or damaged. Do not disas-
semble the pump as individual parts are not available. The pump is only available as a complete assembly. The
pickup screen, hose, and tube are the only serviceable parts and are available separately.
ASSEMBLY
BEARINGS AND SEALS
1. Remove the input shaft bearing snap-ring from the
front case half with suitable snap-ring pliers.
2. Remove the input shaft bearing from the front case
half with Bearing Installer 6953 (3) and Universal
Handle C-4171 (2).
3. Install the input shaft bearing into the front case
half with Bearing Cup Installer 8151 (3) inverted on
Universal Handle C-4171 (2).
4. Install the input shaft bearing snap-ring into the
front case half with suitable snap-ring pliers.

13. Install the transfer case position sensor or switch
(2). Tighten the sensor or switch to 20-34 Nꞏm
(15-25 ft. lbs.) torque.
14. Install manual shift lever (3)and spacer onto sec-
tor shaft (1).
15. Install washer and nut on sector shaft to secure
shift lever. Apply 1-2 drops Mopar
Lock N’ Seal,
or equivalent, to nut threads before installation.
Then tighten nut to 27-34 Nꞏm (20-25 ft. lbs.)
torque.
16. Install new o-ring (1) on detent plug (2).

LEVER-SHIFT
REMOVAL
1. Shift transfer case into 2H.
2. Raise and support the vehicle.
3. Loosen adjusting trunnion lock bolt and slide shift rod out of trunnion.If rod lacks enough travel to come out of
trunnion, push trunnion out of shift lever.
4. Lower vehicle.
5. Remove transfer case shifter knob cap.
6. Remove nut holding shifter knob (2) to shift lever.
7. Remove shifter knob.
8. Remove the shift boot from the shifter console.
9. Remove the bolts securing the shifter mechanism to the floor pan.
10. Separate shift lever mechanism from the vehicle.
Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2-SHIFTERKNOB 5-ALIGNMENTPIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE

REMOVAL
1. Shift transfer case into 2WD.
2. Raise vehicle.
3. Drain transfer case lubricant.
4. Mark front and rear propeller shafts for alignment
reference.
5. Support transmission with jack stand.
6. Remove the transfer case skid plate, if equipped.
7. Disconnect front and rear propeller shafts at trans-
fer case.
8. Disconnect transfer case shift motor and mode
sensor wire connectors (3).
9. Disconnect transfer case vent hose.
10. Support transfer case with transmission jack.
11. Secure transfer case to jack with chains.
12. Remove nuts attaching transfer case (2) to transmission (1).
13. Pull transfer case and jack rearward to disengage transfer case.
14. Remove 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.
SHIFT MOTOR ASSEMBLY AND FRONT OUTPUT SHAFT SEAL
1. Remove the bolts (3) which hold the shift motor
and mode sensor assembly (2) to the transfer case
(1).

Inspect the shift fork wear pads (3, 4). The mode (2)
and range (1) fork pads are serviceable and can be
replaced if necessary.
Check both of the sleeves for wear or damage, espe-
cially on the interior teeth. Replace the sleeves if wear
or damage is evident.
REAR EXTENSION HOUSING
Inspect the extension housing seal and bushing. Replace both components if either show any sign of wear or dam-
age.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
Inspect the shaft threads, sprocket teeth, and bearing surfaces. Minor nicksontheteethcanbesmoothedwithan
oilstone. Use 320-400 grit emery to smooth minor scratches on the shaft bearing surfaces. Rough threads on the
shaft can be chased if necessary. Replace the shaft if the threads are damaged, bearing surfaces are scored, or if
any sprocket teeth are cracked or broken.
Examine the drive chain and shaft bearings. Replace the chain and both sprockets if the chain is stretched, dis-
torted, or if any of the links bind. Replace the bearings if rough, or noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear (2) condition carefully. The gear
is only serviced as part of the front case (1). If the
gear is damaged, it will be necessary to replace the
gear and front case as an assembly. Do not attempt to
remove the gear.
FRONT AND REAR CASES
Inspect the cases for wear and damage.
Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces. Also
make sure the front case mounting studs are in good condition.
Check the front case mounting studs and vent tube. The tube can be secured with Loctite™ 271 or 680 if loose.
Thestudthreadscanbecleanedupwithadieifnecessary.Alsocheckcondition of the fill/drain plug threads in the
rear case. The threads can be repaired with a thread chaser or tap if necessary. Or the threads can be repaired with
Helicoil
stainless steel inserts if required.

REAR EXTENSION
1. Install new seal in rear extension housing seal with
Installer D-163 and Universal Handle C-4171..
2. Apply bead of Mopar
Gasket Maker, or equivalent,
to mating surface of rear extension housing. Keep
sealer bead width to maximum of 3/16 inch. Do not
use excessive amount of sealer as excess could
be displaced into output bearing.
3. Align and install rear extension (1) on the transfer
case (2).
4. Apply Mopar
Silicone Sealer to threads of rear
extension housing bolts. Then install and tighten
bolts to 16-24 Nꞏm (12-18 ft. lbs.) torque.
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 - NV243
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 16-24 12-18 -
Bolt, Case Half 20-27 15-24 -
Screw, Oil Pump 12-16 8-12 -
Nuts, Mounting 30-41 20-30 -
Bolts, Shift Motor and
Mode Sensor Assembly16-24 12-18 -

REMOVAL
1. Shift transfer case into AWD.
2. Raise vehicle.
3. Drain transfer case lubricant.
4. Mark front and rear propeller shafts for alignment
reference.
5. Support transmission with jack stand.
6. Remove the transfer case skid plate, if equipped.
7. Disconnect front and rear propeller shafts at trans-
fer case.
8. Disconnect transfer case shift motor and mode
sensor wire connectors (3).
9. Disconnect transfer case vent hose.
10. Support transfer case with transmission jack.
11. Secure transfer case to jack with chains.
12. Remove nuts attaching transfer case to transmission (1).
13. Pull transfer case and jack rearward to disengage transfer case.
14. Remove 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.
SHIFT MOTOR ASSEMBLY AND FRONT OUTPUT SHAFT SEAL
1. Remove the bolts (3) which hold the shift motor
and mode sensor assembly (2) to the transfer case
(1).
2. Remove the shift motor and mode sensor assem-
bly from the transfer case.

REAR EXTENSION HOUSING
Inspect the extension housing seal and bushing. Replace both components if either show any sign of wear or dam-
age.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
Inspect the shaft splines and bearing surfaces. Minor nicks on the splinescanbesmoothedwithanoilstone.Use
320-400 grit emery to smooth minor scratches on the shaft bearing surfaces. Replace the shaft if the bearing sur-
faces are scored or if any of the splines are cracked or broken.
Examine the drive chain and shaft bearings. Replace the chain and both sprockets if the chain is stretched, dis-
torted, or if any of the links bind. Replace the bearings if rough, or noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear (2) condition carefully. The gear
is only serviced as part of the front case (1). If the
gear is damaged, it will be necessary to replace the
gear and front case as an assembly. Do not attempt to
remove the gear.
FRONT AND REAR CASES
Inspect the cases for wear and damage.
Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces. Also
make sure the front case mounting studs are in good condition.
Check the front case mounting studs and vent tube. The tube can be secured with Loctite™ 271 or 680 if loose.
Thestudthreadscanbecleanedupwithadieifnecessary.Alsocheckcondition of the fill/drain plug threads in the
rear case. The threads can be repaired with a thread chaser or tap if necessary. Or the threads can be repaired with
Helicoil
stainless steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the pump if any part appears to beworn or damaged. Do not disas-
semble the pump as individual parts are not available. The pump is only available as a complete assembly. The
pickup screen, hose, and tube are the only serviceable parts and are available separately.

REAR EXTENSION
1. Install new seal in rear extension housing seal with
Seal Installer D-163 and Universal Handle C-4171.
Verify that the weep hole in the rubber is oriented
downward.
2. Apply bead of Mopar
Gasket Maker, or equivalent,
to mating surface of rear extension housing. Keep
sealer bead width to maximum of 3/16 inch. Do not
use excessive amount of sealer as excess could
be displaced into output bearing.
3. Align and install rear extension (1) on the transfer
case (2).
4. Apply Mopar
Silicone Sealer to threads of rear
extension housing bolts. Then install and tighten
bolts to 16-24 Nꞏm (12-18 ft. lbs.) torque.
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 - NV244 GENII
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 16-24 12-18 -
Bolt, Case Half 25-28 18-21 -
Screw, Oil Pump 14-19 10-14 -
Nuts, Mounting 30-41 20-30 -
Bolts, Shift Motor and
Mode Sensor Assembly16-24 12-18 -

REMOVAL
1. Shift transfer case into 2WD.
2. Raise vehicle.
3. Drain transfer case lubricant.
4. Mark front and rear propeller shafts for alignment
reference.
5. Support transmission with jack stand.
6. Remove the transfer case skid plate, if equipped.
7. Disconnect front and rear propeller shafts at trans-
fer case.
8. Disconnect transfer case shift motor and mode
sensor wire connectors (3).
9. Disconnect transfer case vent hose.
10. Support transfer case with transmission jack.
11. Secure transfer case to jack with chains.
12. Remove nuts attaching transfer case (2) to transmission (1).
13. Pull transfer case and jack rearward to disengage transfer case.
14. Remove 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.
COMPANION FLANGE AND EXTENSION HOUSING
1. Install two bolts 180° apart into the front output
shaft companion flange.
2. Place holder (1) over the bolts (2) and against the
companion flange.
3. Remove and discard the front companion flange
nut.
4. 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.