DODGE RAM SRT-10 2006 Service Repair Manual

3. Unseat rear case (1) from alignment dowels.
4. Remove rear case and oil pump assembly from
front case.
CAUTION: Do not remove the bolts holding the oil
pump cover to the rear case half. The oil pump
cover is aligned to the rear output shaft bearing
inner race and will becomemis-aligned if the bolts
are loosened. If the transfer case failure has gen-
erated any debris which may have become
trapped in the oil pump, the rear case and oil
pump assembly MUST be replaced.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Remove shift rail (1) cup (3) and spring (2).
2. Remove front sprocket (1) retaining ring (2).

3. Pull mainshaft (3), front sprocket (1) and chain out-
ward about 25.4 mm (1-inch) simultaneously.
4. Remove chain from mainshaft drive sprocket and
remove front sprocket and chain as assembly.
SHIFT FORKS AND MAINSHAFT
1. Remove the transfer case position switch (2).
2. Loosen detent plug (2).
3. Remove detent plug (2), spring (3), and plunger
(4). Note that the plug has an O-ring seal. Remove
and discard this seal.

4. Remove the front output shaft (1) snap-ring (2).
5. Remove front output shaft (2) from bearing in the
front case (1).
6. Pull mainshaft assembly (2) out of input gear,
mode sleeve, and front case (1).

7. Remove mode fork (1), mode sleeve (3), and shift
rail (2) as assembly. Note which way the sleeve fits
in the fork (long side of sleeve goes to front).
8. Remove range fork retaining ring.
9. Remove range fork (2) and hub (1) as an assem-
bly. Note fork position for installation reference.
10. Remove the shift sector support (1).

11. Remove shift sector (1).
MAINSHAFT
1. Remove the drive sprocket retaining ring (2) from
the output shaft (1).
2. Remove the drive sprocket (3) thrust washer (2)
from the output shaft (1).

3. Remove drive sprocket (2) from the output shaft
(1).
4. Remove the clutch gear (2) from the output shaft
(1).
Remove the sprocket hub (2) from the output shaft
(1).

5. Remove the mode hub (3) retaining ring (2) from
the output shaft (1).
6. Remove the mode hub (2) from the output shaft
(1).
INPUT AND PLANETARY GEAR
1. Remove input gear seal with suitable screw and
slide hammer.
2. Remove input gear (1) retaining ring (2) with heavy
duty snap-ring pliers.

3. Place front case in horizontal position. Then
remove input gear and low range gear as an
assembly (2). Tap gear out of bearing with plastic
mallet, if necessary.
INPUT AND PLANETARY GEAR
1. Remove snap-ring (1) that retains input gear in low
range gear.
2. Remove retainer (3).

3. Remove front tabbed thrust washer (1).
4. Remove input gear (1).
5. Remove rear tabbed thrust washer (2) from low
range gear (1).
CLEANING
Clean the transfer case parts with a standard parts cleaning solvent. Remove all traces of sealer from the cases
and retainers with a scraper and 3M™ all purpose cleaner. Use compressed air to remove solvent residue from oil
feed passages in the case halves, retainers, gears, and shafts.

INSPECTION
MAINSHAFT/SPROCKET/HUB
Inspect the splines on the hub and shaft and the teeth on the sprocket. Minornicks and scratches can be smoothed
with an oilstone, however, replace any part that is damaged.
Check the contact surfaces in the sprocket bore and on the mainshaft. Minornicks and scratches can be smoothed
with 320-400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the input gear (6). Minor nicks can be dressed off with an oilstone but replace the gear if any
teeth are broken, cracked, or chipped. The bearing surface on the gear can besmoothedwith300-400gritemery
cloth if necessary.
Examine the planetary carrier body (1) and pinion gears for wear or damage.The carrier will have to be replaced
as an assembly if the body, pinion pins, or pinion gears are damaged.
Check the carrier lock ring (4) and both thrust washers (2, 3) for wear or cracks. Replace them if necessary. Also
replace the carrier lock retaining ring (5) if bent, distorted, or broken.
Input Gear And Carrier Components
1 - PLANETARY CARRIER 4 - CARRIER LOCK RING
2 - REAR THRUST WASHER 5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER 6 - INPUT GEAR