DODGE RAM SRT-10 2006 Service Repair Manual

3. Install the Number 10 check ball (1) into the trans-
fer plate. The check ball is approximately 4.8 mm
(3/16 in.) in diameter.
4. Position lower housing separator plate (3) on trans-
fer plate (2).
5. Install lower housing (2) on assembled transfer
plate (4) and upper housing (3).
6. Install and start all valve body screws by hand
except for the screws to hold the boost valve tube
brace. Save those screws for later installation.
Then tighten screws evenly to 4 Nꞏm (35 in. lbs.)
torque. Start at center and work out to sides when
tightening screws (1).
UPPER HOUSING VALVE AND PLUG
Refer to the following graphics , and to perform the following steps.

1. Lubricate valves, plugs, springs with clean transmission fluid.
2. Install the boost valve plug (4), boost valve (3), spring (1), and retainer (2) into the housing.
3. Install the boost valve cover (14). Tighten cover plate screws to 4 Nꞏm (35 in. lbs.) torque.
4. Install shuttle valve as follows:
a. Insert plastic guides (5) in shuttle valve secondary spring (7) and install spring on end of shuttle valve (9).
b. Install shuttle valve (9) into housing.
c. Hold shuttle valve in place.
d. Compress secondary spring (7) and install E-clip (6) in groove at end of shuttle valve.
e. Verify that spring and E-clip are properly seated before proceeding.
5. Install shuttle valve cover plate (8). Tighten cover plate screws to 4 Nꞏm (35 in. lbs.) torque.

6. Install 1-2 (9) and 2-3 (12) valve governor plugs in valve body.
7. Install shuttle valve primary spring (13) and throttle plug (11).
8. Align and install governor plug cover (11). Tighten cover screws to 4 Nꞏm(35 in. lbs.) torque.
9. Install the switch valve (3).
10. Install the throttle valve and spring (7), kickdown (5), and kickdown detent (6).
11. Install the manual valve (8).
12. Assemble regulator valve (2) and spring (4). Insert assembly in upper housing.

13. Install 1-2 (2) and 2-3 (3) shift valves and springs.
14. Install 1-2 shift control valve and spring (9).
15. Install retainer (8), limit valve and spring (7), and 2-3 throttle plug(4) into the limit valve housing (5).
16. Install the throttle pressure spring and plug (12) and plug sleeve (11).
17. Install pressure plug cover (10) and cover plate (6). Tighten screws to4Nꞏm(35in.lbs.).
18. Install limit valve housing (5) and cover plate (6). Tighten screws to 4Nꞏm (35 in. lbs.).
BOOST VALVE TUBE AND BRACE
1. Position valve body assembly so lower housing (2)
is facing upward.
2. Lubricate tube ends and housing ports with trans-
mission fluid or petroleum jelly.
3. Start tube in lower housing port first. Then swing
tube downward and work opposite end of tube into
upper housing port.
4. Insert and seat each end of tube in housings.
Upper Housing Shift Valve and Pressure Plug Locations
1 - UPPER HOUSING 7 - LIMIT VALVE AND SPRING
2 - 1-2 SHIFT VALVE AND SPRING 8 - RETAINER
3 - 2-3 SHIFT VALVE AND SPRING 9 - 1-2 SHIFT CONTROL VALVE AND SPRING
4 - 2-3 THROTTLE PLUG 10 - PRESSURE PLUG COVER
5 - LIMIT VALVE HOUSING 11 - PLUG SLEEVE
6 - LIMIT VALVE COVER 12 - THROTTLE PRESSURE SPRING AND PLUG

5. Slide tube brace (2) under tube and into alignment
with valve body screw holes.
6. Install and finger tighten three screws that secure
tube brace to valve body housings.
7. Bend tube brace tabs up and against tube to hold it
in position.
8. Tighten all valve body housing screws to 4 Nꞏm (35
in. lbs.) torque after tube and brace are installed.
Tighten screws in diagonal pattern starting at cen-
ter and working outward.
3-4 ACCUMULATOR
1. Position converter clutch valve (4) and 3-4 shift
valve (3) springs in housing.
2. Loosely attach accumulator housing (2) with right-
side screw (1). Install only one screw at this time
as accumulator must be free to pivot upward for
ease of installation.
3. Install 3-4 shift valve and spring (3).

4. Position plug (2) on end of converter clutch valve
spring. Then compress and hold springs and plug
in place with fingers of one hand.
5. Swing accumulator housing upward over valve
springs and plug.
6. Hold accumulator housing firmly in place and install
remaining two attaching screws. Be sure springs
and clutch valve plug are properly seated. Tighten
screws to 4 Nꞏm (35 in. lbs.).
VALVE BODY FINAL
1. Insert manual lever detent spring in upper housing.
2. Position detent ball on end of spring. Then hold
detent ball and spring in detent housing with
Retainer Tool 6583 (1).
3. Install throttle lever (1) in upper housing. Then
install manual lever (2) over throttle lever and start
manual lever into housing.
4. Align manual lever with detent ball and manual
valve (3). Hold throttle lever upward. Then press
down on manual lever until fully seated. Remove
detent ball retainer tool after lever is seated.
5. Then install manual lever seal, washer and E-clip.
6. Verify that throttle lever is aligned with end of kick-
down valve (4) stem and that manual lever arm is
engaged in manual valve.

7. Lubricate solenoid case connector (1) O-rings and
shaft of manual lever with light coat of petroleum
jelly.
8. Attach solenoid case connector to 3-4 accumulator
with shoulder-type screw. Connector has small
locating tang that fits indimple at top of accumula-
tor housing (2). Seat tang in dimple before tighten-
ing connector screw.
9. Install solenoid assembly and gasket. Tighten sole-
noid attaching screws to 8 Nꞏm (72 in. lbs.) torque.
10. Verify that solenoid wire harness is properly
routed. Solenoid harness must be clear of manual
lever and park rod and not be pinched between
accumulator housing and cover.
11. Position line pressure adjusting screw in adjusting
screw bracket.
12. Install switch valve spring on tang at end of
adjusting screw bracket.
13. Position adjusting screw bracket on valve body.
Align valve springs and press bracket into place.
Install short, upper bracket screws first and long
bottom screw last. Verify that valve springs and
bracket are properly aligned. Then tighten all
three bracket screws to 4 Nꞏm (35 in. lbs.) torque.
14. Perform Line Pressure and Throttle Pressure
adjustments. (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC/VALVE BODY - ADJUSTMENTS)
GOVERNOR BODY, SENSOR AND SOLENOID
1. Turn valve body assembly over so accumulator side of transfer plate is facing down.
2. Install new O-rings on governor pressure solenoid and sensor.
3. Lubricate solenoid and sensor O-rings with clean transmission fluid.
4. Install governor pressure sensor in governor body.
5. Install governor pressure solenoid in governor body. Push solenoid in until it snaps into place in body.
6. Position governor body gasket on transfer plate.
7. Install retainer plate on governor body and around solenoid. Be sure solenoid connector is positioned in retainer
cutout.
8. Align screw holes in governor body and transfer plate. Then install and tighten governor body screws to 4 Nꞏm
(35 in. lbs.) torque.
9. Connect harness wires to governor pressure solenoid and governor pressure sensor.
10. Install fluid filter and pan.
11. Lower vehicle.
12. Fill transmission with recommended fluid and road test vehicle to verify repair.

INSTALLATION
1. Check condition of O-ring seals (1) on valve body
harness connector (2). Replace seals on connector
body if cut or worn.
2. Check condition of manual lever shaft seal (2) in
transmission case. Replace seal if lip is cut or
worn. Install new seal with 15/16 deep well socket
(1).
3. Check condition of seals on accumulator piston. Install new piston seals, if necessary.
4. Place valve body manual lever in low (1 position) so ball on park lock rod will be easier to install in sprag.
5. Lubricate shaft of manual lever with petroleum jelly. This will ease inserting shaft through seal in case.
6. Lubricate seal rings on valve body harness connector with petroleum jelly.
7. Position valve body in case and work end of park lock rod into and through pawl sprag. Turn propeller shaft to
align sprag and park lock teeth if necessary. The rod will click as it enterspawl. Move rod to check engagement.
CAUTION: It is possible for the park rod to displace into a cavity just abovethe pawl sprag during instal-
lation. Make sure the rod is actually engaged in the pawl and has not displaced into this cavity.
8. Install accumulator spring and piston into case. Then swing valve body overpistonandouterspringtoholditin
place.
9. Align accumulator piston and outer spring, manual lever shaft and electrical connector in case.
10. Then seat valve body in case and install one or two bolts to hold valve bodyinplace.
11. Tighten valve body bolts alternately and evenly to 11 Nꞏm (100 in. lbs.)torque.
12. Install new fluid filter on valve body. Tighten filter screws to 4 Nꞏm (35 in. lbs.) torque.
13. Install throttle and gearshift levers on valve body manual lever shaft.
14. Check and adjust front and rear bands if necessary.
15. Install the transmission range sensor (Refer to 21 - TRANSMISSION/AUTOMATIC/TRANSMISSION RANGE
SENSOR - INSTALLATION).
16. Connect solenoid case connector wires.
17. Install oil pan and new gasket. Tighten pan bolts to 13.6 Nꞏm (125 in. lbs.) torque.
18. Lower vehicle and fill transmission with Mopar
ATF +4, Automatic Transmission fluid.

19. Check and adjust gearshift and throttle valve cables, if necessary.
ADJUSTMENTS - VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the valve body;
Line Pressure
Throttle Pressure
Line and throttle pressures are interdependent because each affects shift quality and timing. As a result, both
adjustments must be performed properly and in the correct sequence. Adjust line pressure first and throttle pressure
last.
LINE PRESSURE ADJUSTMENT
1. Measure distance (2) from the valve body to the
inner edge of the adjusting screw with an accurate
steel scale. Distance should be 33.4 mm (1-5/16
in.). If adjustment is required, turn the adjusting
screw in, or out, to obtain required distance setting.
NOTE: The 33.4 mm (1-5/16 in.) setting is an
approximate setting. Manufacturing tolerances
may make it necessary to vary from this dimen-
sion to obtain desired pressure.
One complete turn of the adjusting screw changes line
pressure approximately 1-2/3 psi (9 kPa).
Turning the adjustingscrew counterclockwise
increases pressure while turning the screw clockwise
decreases pressure.
THROTTLE PRESSURE ADJUSTMENT
1. Insert Gauge Tool C-3763 between the throttle
lever cam and the kickdown valve stem (2).
2. Push the gauge tool inward to compress the kick-
down valve against the spring and bottom the throt-
tle valve.
3. Maintain pressure against kickdown valve spring.
Turn throttle lever stop screw until the screw head
touches throttle lever tang and the throttle lever
cam touches gauge tool.
NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.

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TRANSFER CASE - ELECTRICAL
DIAGNOSTICS
DIAGNOSIS AND TESTING
C1401- TRANSFER CASE RANGE SELECT
SWITCH CIRCUIT LOW. .................. 1501
C1402- TRANSFER CASE RANGE SELECT
SWITCH CIRCUIT HIGH................... 1506
C1404- TRANSFER CASE RANGE
POSITION SENSOR CIRCUIT LOW......... 1511
C1405- TRANSFER CASE RANGE
POSITION SENSOR CIRCUIT HIGH........ 1515
C1407- TRANSFER CASE BRAKE
CONTROL CIRCUIT LOW.................. 1520
C1408-TRANSFER CASE BRAKE CONTROL
CIRCUIT HIGH............................ 1523
C140B- TRANSFER CASE MOTOR
CONTROL CIRCUIT LOW.................. 1526C140C - TRANSFER CASE MOTOR
CONTROL CIRCUIT HIGH................. 1531
C140D - TRANSFER CASE MOTOR
CONTROL CIRCUIT OPEN................. 1536
C1464-FRONT AXLE DISCONNECT
CONTROL CIRCUIT LOW.................. 1540
C1465-FRONT AXLE DISCONNECT
CONTROL CIRCUIT HIGH................. 1544
C1468-FRONT AXLE DISCONNECT
RETURN CONTROL CIRCUIT LOW......... 1548
C1469-FRONT AXLE DISCONNECT
RETURN CONTROL CIRCUIT HIGH........ 1553
C146A–FRONT AXLE DISCONNECT
RETURN CONTROL CIRCUIT OPEN........ 1557
STANDARD PROCEDURE
TRANSFER CASE VERIFICATION TEST .... 1562