DODGE RAM SRT-10 2006 Service Repair Manual

5.(G303) FRONT AXLE SIGNAL CIRCUIT OPEN
Turn the ignition off.
Disconnect the FAD harness connector.
Disconnect the TIPM C4 harness connector.
Measure the resistance of the (G303) Front Axle Lock Signal circuit
from the TIPM C4 harness connector to the FAD harness connector.
Is the resistance below 5.0 ohms?
Ye s>>
Go To 7
No>>
Repair the (G303) Front Axle Lock Signal for an open.
Perform the TRANSFER CASE VERIFICATION TEST-VER
1. (Refer to 21 - TRANSMISSION/TRANSAXLE/TRANSFER
CASE - STANDARD PROCEDURE)
6.(G304) FRONT AXLE SIGNAL CIRCUIT OPEN
Turn the ignition off to the lock position.
Disconnect the TIPM C2 harness connector.
Measure the resistance of the (G304) Front Axle Lock Signal circuit
from the TIPM C2 harness connector to the FAD harness connector.
Is the resistance below 5.0 ohms?
Ye s>>
Go To 8
No>>
Repair the (G304) Front Axle Lock Control for an open.
Perform the TRANSFER CASE VERIFICATION TEST-VER
1. (Refer to 21 - TRANSMISSION/TRANSAXLE/TRANSFER
CASE - STANDARD PROCEDURE)

7.FRONT AXLE DISCONNECT (FAD) MODULE
Using the wiring diagram/schematic as a guide, inspect all wiring and connectors that pertain to this circuit.
Were any problems found?
Ye s>>
Repair as necessary.
Perform the TRANSFER CASE VERIFICATION TEST-VER 1. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/TRANSFER CASE - STANDARD PROCEDURE)
No>>
Replace the Front Axle Disconnect (FAD) Module in accordance with the Service Information.
Perform the TRANSFER CASE VERIFICATION TEST-VER 1. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/TRANSFER CASE - STANDARD PROCEDURE)
8.TOTALLY INTEGRATED POWER MODULE (TIPM)
Using the wiring diagram/schematic as a guide, inspect all wiring and connectors that pertain to this circuit.
Were any problems found?
Ye s>>
Repair as necessary.
Perform the TRANSFER CASE VERIFICATION TEST-VER 1. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/TRANSFER CASE - STANDARD PROCEDURE)
No>>
Replace the Totally Integrated Power Module (TIPM) in accordance with theService Information.
Perform the TRANSFER CASE VERIFICATION TEST-VER 1. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/TRANSFER CASE - STANDARD PROCEDURE)
9.INTERMITTENT WIRING AND CONNECTORS
The conditions necessary to set this DTC are not present at this time.
Using the schematics as a guide, inspect the wiring and connectors specifictothiscircuit.
Wiggle test the wiring harness and connectors while checking for shorted and open circuits.
Using the scan tool, monitor the data related to this circuit while performing the wiggle test. Look for the data to
change or for the DTC to reset.
Were there any problems found?
Ye s>>
Repair as necessary.
Perform the TRANSFER CASE VERIFICATION TEST-VER 1. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/TRANSFER CASE - STANDARD PROCEDURE)
No>>
Te s t C o m p l e t e .
STANDARD PROCEDURE

TRANSFER CASE VERIFICATION TEST
1.
Disconnect all jumper wires and reconnect all previously disconnected components and connectors.
With the scan tool, select clear Stored DTCs.
Make sure that all accessories are turned off and that the battery is fully charged.
Test drive the vehicle in each Transfer Case range and verify proper operation in each range.
To select or deselect 2WD, AWD or 4HI mode, vehicle speed must be below 88 Kmh(55 mph) with all wheels
at vehicle speed.
Shifts will not take place with a wheel speed difference of greater than 21 Kmh (13 mph) between the front
and rear wheels.
To select or deselect 4LO (if equipped), vehicle speed must be below 5 Kmh (3mph) with the ignition ON and
the transmission in neutral (auto trans) or the clutch pedal pressed (man trans).
To select or deselect Transfer Case Neutral, vehicle speed must be 0 Kmh (0 mph) with the ignition ON,
engine OFF, the brake pedal applied, and the transmission in neutral (autotrans) or the clutch pedal pressed
(man trans). Press the Neutral button (if equipped) on the Transfer Case Selector Switch until the Neutral Indi-
cator is illuminated.
WARNING: Apply the parking brake. The vehicle may roll with the Transfer Case in neutral.
To verify that the Transfer Case is in Neutral, shift the automatic transmission into reverse and release the
brake pedal for three seconds or shift the manual transmission into gear andslowlyreleasetheclutchpedal.
There should be no vehicle movement if the Transfer Case is in Neutral.
With the scan tool, select View DTCs in the Totally Integrated Power Module(TIPM) and in the Instrument Cluster.
Are there any DTCs present in the Totally Integrated Power Module (TIPM) orin the Instrument Cluster?
Ye s>>
Return to the symptom list and perform the appropriate diagnostic test.
No>>
Repair is complete.

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TRANSFER CASE - NV241 GENII - SERVICE
INFORMATION
DESCRIPTION ............................. 1564
OPERATION ............................... 1564
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV241 GENII ...................... 1565
REMOVAL ................................. 1566
DISASSEMBLY ............................. 1566
CLEANING ................................. 1578
INSPECTION ............................... 1579
ASSEMBLY . ............................... 1581
INSTALLATION ............................. 1594
SPECIFICATIONS
TRANSFER CASE - NV241 GENII .......... 1594
SPECIAL TOOLS
TRANSFER CASE - NV241/NV243 ......... 1596SEAL-EXTENSION HOUSING
REMOVAL ................................. 1598
INSTALLATION ............................. 1598
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL ................................... 1599
FRONTOUTPUTSHAFTSEAL
REMOVAL ................................. 1600
INSTALLATION ............................. 1601
LEVER-SHIFT
REMOVAL ................................. 1602
INSTALLATION ............................. 1603
ADJUSTMENTS
ADJUSTMENT - SHIFT LEVER............. 1604

TRANSFER CASE - NV241 GENII - SERVICE INFORMATION
DESCRIPTION
The NV241 GENII transfer case (1) is a part-time
transfer case with a low-range gear system. It pro-
vides three operating ranges plus a NEUTRAL posi-
tion. The low range position provides a gear reduction
ratio of 2.72:1 for increased low speed torque capabil-
ity.
The gear cases and extension are all of aluminum.
Drive sprockets and an interconnecting drive chain are
used to transmit engine torque to the front/rear propel-
ler shafts. The mainshaft, input gear and front output
shaft are supported by ball and needle bearings.
IDENTIFICATION
An identification tag (2) is attached to the rear case of
every transfer case. The tag provides the transfer
case model number, assembly number, serial number,
and low range ratio.
The transfer case serial number also represents the
date of build.
OPERATION
OPERATING RANGE
Transfer case operating ranges are:
2H (2-wheel drive).
4H (4-wheel drive).
4LO (4-wheel drive low range.
The 2H range is for use on any road surface at any time.
The 4H and 4LO ranges are for off road use only. They are not for use on hard surface roads. The only exception
being when the road surface is covered by ice and snow.
The low range reduction gear system is operative in 4LO range only. This range is for extra pulling power in off road
situations. Low range reduction ratio is 2.72:1.
SHIFT MECHANISM
The transfer case is operated by an adjustable floor mounted shift linkage. The transfer case shift lever is directly
attached to the shift sector. The sector operates the range and mode forks within the transfer case.

A straight line shift pattern is used with a NEUTRAL detent. Lever range positions are imprinted in the shift knob.
SHIFTING
The transfer case can be shifted between the 2H and 4H operating ranges while the vehicle is in motion. The vehi-
cle must have the transmission placed in NEUTRAL, or the clutch depressed in the case of a manual transmission,
and be moving less than 2-3 MPH when shifting into and out of the 4L operatingrange.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV241 GENII
Before beginning repair on a suspected transfer case malfunction, check all other driveline components beforehand.
The actual cause of a problem may be related to such items as: front hubs, axles, propeller shafts, wheels and tires,
transmission, or clutch instead. If all other driveline components are ingood condition and operating properly, refer
to the Diagnosis Chart for further information.
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer Case difficult to shift or will
not shift into desired range.1) Vehicle speed too great to permit
shifting.1) Stop vehicle and shift into
desired range. Or, reduce speed to
below 3-4 km/h (2-3 mph) before
attempting the shift.
2) If vehicle was operated for an
extended period in 4H on a dry
paved surface, the driveline torque
load may be causing a bind.2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate
vehicle in 2H on dry paved
surfaces.
3) Transfer case external shift
linkage binding.3) Lubricate, repair, or replace
linkage bushings, or tighten loose
components as necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill to edge of fillhole
with Mopar
ATF +4, Automatic
Transmission fluid.
5) Internal components binding,
worn, or damaged.5) Disassemble the transfer case
and replace worn or damaged
components as necessary.
Transfer Case noisy in all operating
ranges.1) Insufficient or incorrect lubricant. 1) Drain and refill to edge of fillhole
with Mopar
ATF +4, Automatic
Transmission fluid.
Noisy in, or jumps out of, four wheel
drive low range.1) Transfer case not completely
engaged in 4L position.1) With the transmission in
NEUTRAL, or the clutch depressed
in the case of a manual
transmission and the vehicle moving
under 3-4 km/h (2-3 mph), shift the
transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair
linkage as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.4) Disassemble unit and repair as
necessary.
5) Low range gear worn or
damaged.5) Disassemble unit and repair as
necessary.

Condition Possible Cause Correction
Lubricant leaking from output shaft
seal or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Vent closed or restricted. 2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or
installed incorrectly.3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.1) Operate vehicle in the 2H
position on hard, dry surfaces.
REMOVAL
1. Raise and support vehicle.
2. Remove skid plate, if equipped. (Refer to 13 - FRAMES & BUMPERS/FRAME/TRANSFER CASE SKID PLATE
- REMOVAL)
3. Position drain oil container under transfer case.
4. Remove transfer case drain plug and drain lubricant into container.
5. Disconnect vent hose and transfer case position sensor connector.
6. Disconnect shift rod from grommet in transfer case shift lever, or from floor shift arm whichever provides easy
access. Use channel lock style pliers to press rod out of lever grommet.
7. Support transmission with jack stand.
8. Mark front and rear propeller shafts for assembly reference.
9. Remove front and rear propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - REMOVAL)
10. Support transfer case with suitable jack. Secure transfer case to jackwith safety chains.
11. Remove nuts attaching transfer case to transmission.
12. Move transfer case assembly rearward until free of transmission outputshaft.
13. Lower jack and move 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 LEVER AND FRONT OUTPUT SHAFT SEAL
1. Shift transfer case into NEUTRAL.
2. Remove nut that retains the shift lever (1) to sector
shaft. Then remove shift lever from shaft.

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.

6. Using a suitable pry tool (2), remove the slinger (1)
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.
REAR EXTENSION
1. Remove rear extension (1) bolts.
2. Remove rear extension housing (1). Tap extension
once or twice with a plastic mallet to break sealer
bead and loosen it.

3. Remove output bearing (2) retaining ring (3) with
heavy duty snap-ring pliers.
OIL PUMP AND REAR CASE
1. Remove rear case(1)-to-front case (2) bolts (3).
2. Loosen rear case (1) with pry tool to break sealer
bead. Insert tool in slot (3) at each end of case.