boot DODGE RAM SRT-10 2006 Service Owner's Manual

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.

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

INSTALLATION
1. If the shifter mechanism does not have a adjustment locating pin installed, align the adjustment channel on the
shifter assembly to the locating hole in the lower shift lever and install an appropriately sized pin to retain the
position.
2. Position shift lever in vehicle.
3. Install the bolts to hold the shifter mechanism (4) to the floor pan.
4. Raise vehicle.
5. Verify that the transfer case is still in the 2H position. The 2H detent position on the transfer case shift arm is the
second position from full forward.
6. Install trunnion to shift lever, if necessary.
7. Install shift rod to trunnion, if necessary.
8. Tighten the shift rod lock bolt to 10 Nꞏm (90 in.lbs.).
9. Remove the shifter adjustment locating pin from the adjustment channeland the locating hole.
10. Lower vehicle.
11. Install the transfer case shifter console.
12. Install the shifter boot and the shifter knob onto the shifter lever.
13. Install nut to hold shifter knob to shift lever.
14. Install shifter knob cap.
15. Verify transfer case operation.
Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2-SHIFTERKNOB 5-ALIGNMENTPIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE

ADJUSTMENTS
ADJUSTMENT - SHIFT LEVER
1. Move shift lever into 2H position.
2. Raise vehicle.
3. Loosen shift rod lock bolt at trunnion.
4. Check shift rod fit in trunnion. Be sure rod does not bind in trunnion. Lubricate the shift rod and trunnion if nec-
essary.
5. Verify that transfer case shift lever is in 2H detent position. The 2H detent position on the transfer case shift arm
is the second position from full forward.
6. Align the adjustment locating hole on the lower shifter lever with the adjustment channel on the shifter bracket
assembly.
7. Insert an appropriately sized pin through into the adjustment channel and through the locating hole to hold the
shifter in the correct position.
8. Tighten shift rod lock bolt to 10 Nꞏm (90 in. lbs.) torque.
9. Remove the locating pin from the adjustment channel and locating hole.
10. Check shift linkage operation. Be sure transfer case shifts into and operates properly in all ranges.
Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2-SHIFTERKNOB 5-ALIGNMENTPIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE

2. Remove the shift motor and mode sensor assem-
bly from the transfer case.
3. Remove the front propeller shaft seal boot (1)
retaining clamp (2).
4. Remove the front propeller shaft seal boot (1).
5. Remove the front output shaft seal slinger (1) by
bending (2) the slinger ears away from the transfer
case.

5. Install 4-5 rear case (1)-to front case (2) bolts (3) to
hold rear case in position. Tighten bolts snug but
not to specified torque at this time.
CAUTION: Verify that shift rail, and case alignment
dowels are seated before installing any bolts.
Case could be cracked if shaft rail or dowels are
misaligned.
6. Apply Loctite™ 242 to remainder of rear case-to-
front case bolt threads and install bolts. Tighten
bolts to 20-27 Nꞏm (15-24 ft. lbs.).
7. Install rear output bearing (2) snap-ring (3) to out-
put shaft (1).
SEAL BOOT AND SHIFT MOTOR ASSEMBLY
1. Install the front output shaft seal slinger with Installer 8840. Install the slinger onto the shaft until the tool contacts
the rear of the output shaft.
2. Install a new seal boot clamp onto the seal boot.
3. Install the seal boot and clamp onto the slinger hub and tighten the clampwith Crimp Tool C-4975-A.
4. Position the shift motor and mode sensor assembly onto the transfer case.
5. Install the bolts to hold the shift motor and mode sensor assembly to the transfer case. Tighten the bolts to 16-25
Nꞏm (12-18 ft. lbs.).

SEAL-FRONT OUTPUT SHAFT
REMOVAL
1. Remove the front propeller shaft (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL).
2. Remove the front propeller shaft seal boot (1)
retaining clamp (2).
3. Remove the front propeller shaft seal boot (1).
4. Remove the front output shaft seal slinger (1) by
bending (2) the slinger ears away from the transfer
case.

5. Using a suitable pry tool (2), remove the slinger (1)
from the output shaft using care not to damage the
shaft.
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 output shaft seal slinger with Oil Slinger Installer 8840. Install the slinger onto the shaft until the
tool contacts the rear of the output shaft.
3. Install a new seal boot clamp onto the seal boot.
4. Install the seal boot and clamp onto the slinger hub and tighten the clampwith Crimp Tool C-4975-A.
5. Install front propeller shaft (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPELLER
SHAFT - INSTALLATION).

3. Remove the front propeller shaft seal boot (1)
retaining clamp (2).
4. Remove the front propeller shaft seal boot (1).
5. Remove the front output shaft seal slinger (1) by
bending (2) the slinger away from the transfer
case.
6. Using a suitable pry tool, remove the slinger from
the output shaft using care not to damage the
shaft.
7. Using a screw and a slide hammer, remove the
front output shaft seal.

6. Install 4-5 rear case-to front case bolts (3) to hold
rear case (1) in position. Tighten bolts snug but not
to specified torque at this time.
CAUTION: Verify that shift rail, and case alignment
dowels are seated before installing any bolts.
Case could be cracked if shaft rail or dowels are
misaligned.
7. Apply Mopar
Lock ’n Seal Adhesive to remainder
of rear case-to-front case bolt threads and install
bolts. Tighten bolts to 25-28 Nꞏm (18-21 ft. lbs.),
SEAL BOOT AND SHIFT MOTOR ASSEMBLY
1. Install a new seal boot clamp onto the seal boot.
2. Install the seal boot (2) and clamp onto the slinger
(2) hub and tighten the clamp with Crimp Tool
C-4975-A.
3. Position the shift motor and mode sensor assembly
onto the transfer case.
4. Install the bolts (3) to hold the shift motor and
mode sensor assembly (2) to the transfer case (1).
Tighten the bolts to 16-25 Nꞏm (12-18 ft. lbs.).