DODGE RAM SRT-10 2006 Service Repair Manual

DISASSEMBLY
1. Mark position of support (2) in oil pump body (1)
for assembly alignment reference. Use scriber or
paint to make alignment marks.
2. Place pump body on two wood blocks.
3. Remove reaction shaft support bolts and separate
support (2) from pump body (1).
4. Remove pump inner (3) and outer gears (4).

5. Remove o-ring seal (11) from pump body. Discard seal after removal.
6. Remove oil pump seal (1). Discard seal after removal.
CLEANING
Clean pump and support components with solvent and dry them with compressedair.
INSPECTION
Check condition of the seal rings and thrust washer on the reaction shaft support. The seal rings do not need to be
replaced unless cracked, broken, or severely worn.
Inspect the pump and support components. Replace the pump or support if theseal ring grooves or machined sur-
faces are worn, scored, pitted, or damaged. Replace the pump gears if pitted, worn chipped, or damaged.
Inspect the pump bushing. Then check the reaction shaft support bushing. Replace either bushing only if heavily
worn, scored or damaged. It is not necessary to replace the bushings unlessthey are actually damaged.
Oil Pump Assembly
1 - OIL SEAL 7 - BOLTS (6)
2 - VENT BAFFLE 8 - #1 THRUST WASHER (SELECTIVE)
3 - OIL PUMP BODY 9 - INNER GEAR
4 - GASKET 10 - OUTER GEAR
5 - REACTION SHAFT SUPPORT 11 - “O” RING
6 - SEAL RINGS 12 - TORQUE CONVERTER SEAL RING

Clearance between outer gear and reaction shaft
housing should be 0.010 to 0.063 mm (0.0004 to
0.0025 in.). Clearance between inner gear and reac-
tion shaft housing should be 0.010 to 0.063 mm
(0.0004 to 0.0025 in.). Both clearances can be mea-
sured at the same time by installing the gears in the
pump body and measure pump component clearances
as follows:
1. Position an appropriate piece of Plastigage™
across both gears.
2. Align the Plastigage™ to a flat area on the reaction
shaft housing.
3. Install the reaction shaft to the pump housing.
4. Separate the reaction shaft housing from the pump
housing and measure the Plastigage™ following
the instructions supplied with it.
Clearance between inner gear tooth (2) and outer gear (3) should be 0.051 to0.19 mm (0.002 to 0.0075 in.). Mea-
sure clearance with an appropriate feeler gauge (1).
Clearance between outer gear and pump housing should be 0.10 to 0.229 mm (0.004 to 0.009 in.). Measure clear-
ance with an appropriate feeler gauge.

ASSEMBLY
1. Lubricate pump gears (9, 10) with transmission fluid and install them inpump body (3).
2. Install thrust washer (8) on reaction shaft (5) support hub. Lubricate washer with petroleum jelly or transmission
fluid before installation.
3. If reaction shaft seal rings (6) are being replaced, install new seal rings on support hub. Lubricate seal rings with
transmission fluid or petroleum jelly after installation. Squeeze each ring until ring ends are securely hooked
together.
CAUTION: The reaction shaft support seal rings will break if overspread, or twisted. If new rings are being
installed, spread them only enough forinstallation. Also be very sure thering ends are securely hooked
together after installation. Otherwise, the rings will either prevent pump installation, or break during instal-
lation.
4. Align and install reaction shaft support (5) on pump body (3).
5. Install bolts (7) attaching reaction shaft support to pump. Tighten bolts to 20 Nꞏm (175 in. lbs.) torque.
6. Install new o-ring (11) on pump body. Lubricate oil seal and o-ring with petroleum jelly.
Oil Pump Assembly
1 - OIL SEAL 7 - BOLTS (6)
2 - VENT BAFFLE 8 - #1 THRUST WASHER (SELECTIVE)
3 - OIL PUMP BODY 9 - INNER GEAR
4 - GASKET 10 - OUTER GEAR
5 - REACTION SHAFT SUPPORT 11 - “O” RING
6 - SEAL RINGS 12 - TORQUE CONVERTER SEAL RING

7. Install new pump seal (3) with Installer Tool
C-3860-A (1). Use hammer or mallet to tap seal
into place.

BEARING-OUTPUT SHAFT FRONT
REMOVAL
1. Remove overdrive unit from the vehicle.
2. Remove overdrive geartrain (5) from housing.
3. Remove snap-ring (2) holding output shaft front
bearing (1) to overdrive geartrain (5).
4. Pull bearing (1) from output shaft (3).
INSTALLATION
1. Place replacement bearing (1) in position on
geartrain (5) with locating retainer groove toward
the rear.
2. Push bearing (1) onto output shaft (3) until the
snap-ring groove is visible.
3. Install snap-ring (2) to hold bearing onto output
shaft (3).
4. Install overdrive geartrain (5) into housing.
5. Install overdrive unit in vehicle.

BEARING-OUTPUT SHAFT REAR
REMOVAL
1. Remove overdrive unit from the vehicle. (Refer to
21 - TRANSMISSION/AUTOMATIC/OVERDRIVE -
REMOVAL)
2. Remove overdrive geartrain from housing.
3. Remove snap-ring (3) holding output shaft rear
bearing (1) into overdrive housing (2).
4. Using a suitable driver inserted through the rear
end of housing, drive bearing from housing.
INSTALLATION
1. Place replacement bearing (1) in position in hous-
ing (2).
2. Using a suitable driver, drive bearing (1) into hous-
ing (2) until the snap-ring groove is visible.
3. Install snap-ring (3) to hold bearing into housing.
4. Install overdrive geartrain into housing.
5. Install overdrive unit in vehicle.

CLUTCH-OVERDRIVE
DESCRIPTION
The overdrive clutch is composed of the pressure plate (2), clutch plates,holding discs, overdrive piston retainer,
piston, piston spacer, and snap-rings. The overdrive clutch is the forwardmost component in the transmission over-
drive unit and is considered a holding component. The overdrive piston retainer, piston, and piston spacer are
located on the rear of the main transmission case.
NOTE: The number of discs and plates may vary with each engine and vehicle combination.
OPERATION
To apply the clutch, pressure is applied between the piston retainer and piston. The fluid pressure is provided by the
oil pump, transferred through the control valves and passageways, and enters the clutch through passages at the
lower rear portion of the valve body area. With pressure applied between the piston retainer and piston, the piston
moves away from the piston retainer and compresses the clutch pack. This action applies the clutch pack, allowing
torque to flow through the intermediate shaft into the overdrive planetary gear set. The overdrive clutch discs are
attached to the overdrive clutch hub while the overdrive clutch plates, reaction plate, and pressure plate are lugged
to the overdrive housing. This allows the intermediate shaft to transfer the engine torque to the planetary gear and
overrunning clutch. This drives the planetary gear inside the annulus, which is attached to the overdrive clutch drum
and output shaft, creating the desired gear ratio. The waved snap-ring is used to cushion the application of the
clutch pack for the 5 disc version of the overdrive clutch. The 6 disc overdrive clutch does not use a waved snap-
ring.
Overdrive Clutch
1 - REACTION PLATE 2 - PRESSURE PLATE

UNIT-OVERDRIVE
REMOVAL
1. Shift transmission into PARK.
2. Raise vehicle.
3. Remove transfer case, if equipped.
4. Mark propeller shaft universal joint(s) and axle pinion yoke, or the companion flange and flange yoke, for align-
ment reference at installation, if necessary.
5. Disconnect and remove the rear propeller shaft, if necessary. (Refer to3 - DIFFERENTIAL & DRIVELINE/PRO-
PELLER SHAFT/PROPELLER SHAFT - REMOVAL)
6. Remove transmission oil pan, remove gasket, drain oil and reinstall pan.
7. If overdrive unit had malfunctioned, or if fluid is contaminated, remove entire transmission. If diagnosis indicated
overdrive problems only, remove just the overdrive unit.
8. Support transmission with transmission jack.
9. Remove bolts (2) attaching overdrive unit (1) to
transmission.
CAUTION: Support the overdrive unit with a jack
before moving it rearward. This is necessary to
prevent damaging the intermediate shaft. Do not
allow the shaft to support the entire weight of the
overdrive unit.
10. Carefully work overdrive unit off intermediate
shaft. Do not tilt unit during removal. Keep it as
level as possible.
11. If overdrive unit does not require service, immedi-
ately insert Alignment Tool 6227-2 in splines of
planetary gear and overrunning clutch to prevent
splines from rotating out of alignment. If misalign-
ment occurs, overdrive unit will have to be disas-
sembled in order to realign splines.
12. Remove and retain overdrive piston thrust bearing. Bearing may remainon piston or in clutch hub during
removal.
13. Position drain pan on workbench.
14. Place overdrive unit over drain pan. Tilt unit to drain residual fluid from case.
15. Examine fluid for clutch material or metal fragments. If fluid contains these items, overhaul will be necessary.
16. If overdrive unit does not require any service, leave alignment tool inposition. Tool will prevent accidental mis-
alignment of planetary gear and overrunning clutch splines.

DISASSEMBLY
1. Remove transmission speed sensor (2) and o-ring
seal (3) from overdrive case.
2. Remove overdrive piston thrust bearing (1).