torque DODGE RAM SRT-10 2006 Service Repair Manual

SWITCH-POWER STEERING PRESSURE
DESCRIPTION
A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose.
This switch will only be used onHD vehicleswith the 5.7L engines. There is no pressure switch used for the 3.7L,
4.7L, 5.9LDiesel engine or the5.7L LD vehiclepump.
OPERATION
The switch is used on the 5.7L V-8 enginesHD vehicles only.
The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is pro-
vided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM
increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling
under the increased load.
When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch
will open and the PCM will increase the engine idle speed. This will preventthe engine from stalling.
When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle
speed will return to its previous setting.
REMOVAL - 5.7L - HD VEHICLES ONLY
The power steering pressureswitch (5) is installed in
the power steering high-pressure hose (5).
1. Disconnect electrical connector from power steer-
ing pressure switch.
2. Place a small container or shop towel beneath
switch to collect any excess fluid.
3. Remove switch. Use back-up wrench on power
steering line to prevent line bending.
INSTALLATION - 5.7L - HD VEHICLES ONLY
This switch is used only with the 5.7L V-8 enginesHD
vehicles only.
1. Install power steering switch (5) into power steering
line (5).
2. Tighten to 8–11 Nꞏm (70–100 in. lbs.) torque.
3. Connect electrical connector to switch.
4. Check power steering fluid and add as necessary.
5. Start engine and again check power steering fluid.
Add fluid if necessary.

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PUMP - SRT10
DIAGNOSIS AND TESTING - HYDRAULIC
FLOW AND PRESSURE ..................... 93
STANDARD PROCEDURE
INITIAL OPERATION ........................ 95
STANDARD PROCEDURE - FLUID COOLER
LINE QUICK CONNECT FITTING
DISASSEMBLY/ASSEMBLY. ................. 96
REMOVAL .................................... 97
INSTALLATION ............................... 99
SPECIFICATIONS
TORQUE .................................. 100
SPECIAL TOOLS
POWER STEERING ........................ 101
HOSES
REMOVAL
PRESSURE HOSE - PUMP TO FAN ......... 102
PRESSURE HOSE - FAN TO GEAR ......... 102
RETURN HOSE - FAN TO PUMP ............ 103
RETURN HOSE - GEAR TO COOLER ....... 103RETURN HOSE - COOLER TO PUMP ....... 105
INSTALLATION
PRESSURE HOSE - PUMP TO FAN ......... 105
PRESSURE HOSE - FAN TO GEAR ......... 106
RETURN HOSE - FAN TO PUMP ............ 107
RETURN HOSE - GEAR TO COOLER ....... 108
RETURN HOSE - COOLER TO PUMP ....... 108
RESERVOIR
REMOVAL ................................... 109
INSTALLATION .............................. 109
PULLEY
REMOVAL ................................... 110
INSTALLATION .............................. 110
FLUID COOLER TUBE
REMOVAL ................................... 111
INSTALLATION .............................. 112
FLUID COOLER
REMOVAL ................................... 113
INSTALLATION .............................. 115

INSTALLATION
1. Install power steering pump (5).
2. Install three power steering pump mounting bolts.
Tighten mounting bolts to 23 Nꞏm (200 in. lbs.)
torque.
3. Install return hose from fluid cooler on fitting of power steering pump reservoir. Install hose clamp on return hose
past upset bead on power steering reservoir fitting.
4. Install return hose from radiator fan on fitting of power steering pump reservoir. Install hose clamp on return hose
past upset bead on power steering reservoir fitting.
5. Install power steering pressure hose in power steering pump pressure fitting. Tighten pressure hose quick-con-
nect fitting to 28 Nꞏm (21 ft. lbs.) torque.
6. Connect A/C clutch coil wire connector (2).
7. Install accessory drive belt. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
8. Install the air cleaner housing lid and tube assembly (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - INSTALLATION).
9. Install the coolant recovery container (Refer to 7 - COOLING/ENGINE/COOLANT RECOVERY CONTAINER -
INSTALLATION).
10. Connect the battery negative (-) cable to battery negative battery terminal.
11. Fill power steering pump reservoir to correct fluid level. (Refer to 19- STEERING/PUMP/FLUID - STANDARD
PROCEDURE)
12. Perform Power Steering Pump Initial Operation procedure. (Refer to 19- STEERING/PUMP - STANDARD
PROCEDURE).

13. Check for leaks at all hose connections.
SPECIFICATIONS
TORQUE
DESCRIPTION Nꞏm Ft. Lbs. In. Lbs.
Power Steering Line nuts 28 21 —
Power Steering Pump
Mounting Bolts23 17 200

RETURN HOSE - COOLER TO PUMP
NOTE: Review all Warnings and Cautions. (Refer
to 19 - STEERING - WARNING).
CAUTION: Cap all open ends of power steering
hoses, power steering pump fittings and steering
gear ports when disconnected. This will prevent
the entry of foreign material into the components
during servicing.
1. Siphon power steering fluid from fluid reservoir.
2. Remove clamp, then return hose at reservoir.
3. Raise vehicle. (Refer to LUBRICATION & MAINTE-
NANCE/HOISTING - STANDARD PROCEDURE)
4. Remove front air deflector.
5. Disconnect the quick connect fitiing (6) at the
return hose from the metal line at the cooler using
special tool 8875.
INSTALLATION
PRESSURE HOSE - PUMP TO FAN
NOTE: Before installing power steering hose, replace used O-rings as necessary. Clean hose ends and open
ports with a lint-free cloth. Lubricate O-rings with clean power steeringfluid.
1. If pressure hose is separate from quick-connect fittings:
a. Thread quick-connect fitting (8) into cooling fan port. Tighten fittingto28Nꞏm(21ft.lbs.)torque.
b. Slide fan end of pressure hose tube into quick-connect fitting until it locks into place.
2. If pressure hose has quick-connect fittings installed on ends, thread fan end quick-connect fitting into fan port.
Tighten hose fitting to 28 Nꞏm (21 ft. lbs.) torque.
3. Install power steering pressure hose into routing clip (7) on cooling module (5).

4. If pressure hose is separate from quick-connect fittings:
a. Thread quick-connect fitting into power steering pump pressure fitting (10). Tighten hose fitting to 28 Nꞏm (21
ft. lbs.) torque.
b. Slide pump end of pressure hose tube into quick-connect fitting until itlocks into place.
5. If pressure hose has quick-connect fittings installed on ends, thread pump end quick-connect fitting into power
steering pump pressure fitting. Tighten fitting to 28 Nꞏm (21 ft. lbs.) torque.
6. Fill power steering pump reservoir to correct fluid level. (Refer to 19 -STEERING/PUMP/FLUID - STANDARD
PROCEDURE)
7. Perform Power Steering Pump Initial Operation procedure. (Refer to 19 -STEERING/PUMP - STANDARD PRO-
CEDURE).
8. Check for leaks at all hose connections.
PRESSURE HOSE - FAN TO GEAR
NOTE: Before installing power steering hose,
replace used O-rings as necessary. Clean hose
ends and open ports with a lint-free cloth. Lubri-
cate O-rings with clean power steering fluid.
1. Thread power steering pressure hose tube nut on
end of hose into power steering gear port. Tighten
tube nut to 28 Nꞏm (21 ft. lbs.) torque.
2. If fan end of pressure hose is separate from quick-
connect fitting:
a. Thread quick-connect fitting (6) into cooling fan
port (1). Tighten fitting to 28 Nꞏm (21 ft. lbs.)
torque.
b. Slide fan end of pressure hose tube into quick-
connect fitting until it locks into place.
3. If fan end of pressure hose has quick-connect fit-
ting installed, thread fan end quick-connect fitting
into fan port. Tighten fitting to 28 Nꞏm (21 ft. lbs.)
torque.
4. Fill power steering pump reservoir to correct fluid level. (Refer to 19 -STEERING/PUMP/FLUID - STANDARD
PROCEDURE)
5. Perform Power Steering Pump Initial Operation procedure. (Refer to 19 -STEERING/PUMP - STANDARD PRO-
CEDURE).
6. Check for leaks at all hose connections.

RETURN HOSE - GEAR TO COOLER
NOTE: Before installing power steering hose,
replace used O-rings as necessary. Clean hose
ends, fittings and open ports with a lint-free cloth.
Lubricate O-rings with clean power steering fluid.
1. Install return hose into engine compartment using
reverse of how it was removed.
2. Install hose at fluid cooler to the quick connect (1).
3. Install front air deflector.
4. Lower vehicle.
5. Thread return hose tube nut on gear end of hose
into power steering gear port. Tighten tube nut to
28 Nꞏm (21 ft. lbs.) torque.
6. Fill power steering pump reservoir to correct fluid level. (Refer to 19 -STEERING/PUMP/FLUID - STANDARD
PROCEDURE)
7. Perform Power Steering Pump Initial Operation procedure. (Refer to 19 -STEERING/PUMP - STANDARD PRO-
CEDURE).
8. Check for leaks at all hose connections.
RETURN HOSE - COOLER TO PUMP
NOTE: Before installing power steering hose,
replace used O-rings as necessary. Clean hose
ends, fittings and open ports with a lint-free cloth.
Lubricate O-rings with clean power steering fluid.
1. Install hose into engine compartment using reverse
of how it was removed.
2. Reconnect the quick connect fitting (6) of the hose
at fluid cooler (5).
3. Install front air deflector.
4. Lower vehicle.
5. Slide pump end of return hose onto molded fitting
of pump reservoir. Expand hose clamp and slide it
into position on hose past bead formed into reser-
voir fitting.
6. Fill power steering pump reservoir to correct fluid level. (Refer to 19 -STEERING/PUMP/FLUID - STANDARD
PROCEDURE)
7. Perform Power Steering Pump Initial Operation procedure. (Refer to 19 -STEERING/PUMP - STANDARD PRO-
CEDURE).
8. Check for leaks at all hose connections.

8. Measure the gap (1) between the fixture shaft (2)
and the fixture plunger (3). Repeat measurement
on the opposite side of the countershaft cup and
bearing. The average of the two measurements,
will be the size of the countershaft select shim.
9. Install select shim in front housing countershaft
bearing cup bore and install bearing cup.
SPECIFICATIONS
MANUAL TRANSMISSION-G56
TORQUE SPECIFICATIONS
DESCRIPTION Nꞏm Ft. Lbs. In. Lbs.
Fill Plug 57 42 -
Drain Plug 57 42 -
Front to Rear Housing
Bolts58 43 -
Input Shaft Retainer Bolts 23 17 -
Shift Tower bolts 23 17 -
5-6 Shift Fork Bolts 58 43 -
Shift Rail Support bolts 58 43 -
Reverse Idler Gear Shaft
Bolt58 43 -
P.T.O. Cover Bolts 58 43 -
Clutch Release Pivot Ball 22 16 -

8. Install front dust shield (1) tighten bolt to 4.5 Nꞏm
(40 in. lbs.).
9. Install structural cover (3) to transmission bolts and
tighten to 54 Nꞏm (40 ft. lbs.).
10. Install starter motor (2).
11. Install suspension crossmember (4) and tighten
nuts to 102 Nꞏm (75 ft. lbs.).
12. Connect transmission harnesses to clips on case
and connect switches.
13. Install slave cylinder (2) and tighten cylinder nuts
(1)to23Nꞏm(200in.lbs.).
14. Install transfer case and transfer case linkage if
equipped.
15. Remove transmission jack.
16. Install propeller shaft/shafts with reference marks
aligned.
17. Install exhaust on the exhaust manifolds.
18. Fill transmission with lubricant. Correct fill level is
to bottom edge of fill plug hole.
SPECIFICATIONS
MANUAL TRANSMISSION - GETRAG 238
TORQUE SPECIFICATIONS
DESCRIPTION Nꞏm Ft. Lbs. In. Lbs.
Drain Plug 50 37 -
Fill Plug 50 37 -
Shift Tower Bolts 10 - 88
Back Up Lamp Switch Bolt 10 - 88
4x2 Output Flange Bolt200 then loosen and
tighten to 170147 then loosen and
tighten to 125-
4x4 Output Shaft Nut200 then loosen and
tighten to 170147 then loosen and
tighten to 125-
Housing Bolts 22 16 -
Interlock Plate Bolts 10 - 88
Intermediate Support Bolts 22 16 -
Intermediate Support Race
Retainer Bolt22 16 -
Countershaft Bolt 90 66 -

6. Install back up lamp switch (2) connector (1).
7. Install fuel line to top plate stud.
8. Install reverse lockout solenoid (1) harness connec-
tor (2).
9. Install hydraulic clutch quick connector (1) to the
slave cylinder.
10. Clean transmission shifter tower sealing surfaces
and apply a bead of Mopar
Gasket Maker.
11. Install shifter tower and tighten bolts to 18 Nꞏm
(156 in. lbs.).
12. Install propeller shaft with reference marks
aligned.
CAUTION: The drive shaft strap bolts must be
replaced or cleaned and Loctite
242 applied.
CAUTION: Replace drive shaft joint straps when-
ever they are removed. The straps slightly deform
when torqued in place. Reuse of the straps may
result in reduced clamp load on the universal joint
cap.