DODGE RAM SRT-10 2006 Service Repair Manual

SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork shift
rail (2). Minor nicks on the shift rail can be smoothed
with 320-400 grit emery cloth.
Inspect the shift fork wear pads (3, 4). The mode fork
pads are serviceable and can be replaced if neces-
sary. The range fork pads are not serviceable. The
fork must be replaced as an assembly if the pads are
worn or damaged.
Check both of the sleeves for wear or damage, espe-
cially on the interior teeth. Replace the sleeves if wear
or damage is evident.
REAR RETAINER COMPONENTS
Inspect the retainer components. Replace the bearing if rough or noisy. Check the retainer for cracks or wear in the
bearing bore.
Inspect the retaining rings and washers. Replace any part if distorted, bent, or broken. Reuse is not recommended.
Inspect rear extension bushing. Replace if worn or scored.
DRIVE CHAIN
Examine the drive chain and shaft bearings. replace the chain if stretched, distorted, or if any of the links bind.
Replace the bearings if rough, or noisy.

LOW RANGE ANNULUS GEAR
Inspect annulus gear (2) condition carefully. The gear
is only serviced as part of the front case. If the gear is
damaged, it will be necessary to replace the gear and
front case as an assembly. Do not attempt to remove
the gear.
FRONT CASE AND REAR CASE
Inspect the cases for wear and damage.
Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces. Also
make sure the front case mounting studs are in good condition.
Check the front case mounting studs and vent tube. The tube can be secured with Loctite™ 271 or 680 if loose.
Thestudthreadscanbecleanedupwithadieifnecessary.Alsocheckcondition of the fill/drain plug threads in the
rear case. The threads can be repaired with a thread chaser or tap if necessary. Or the threads can be repaired with
Helicoil™ stainless steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the pump if any part appears to beworn or damaged. Do not disas-
semble the pump as individual parts are not available. The pump is only available as a complete assembly. The
pickup screen, hose, and tube are the only serviceable parts and are available separately.
ASSEMBLY
BEARINGS AND SEALS
1. Remove the input shaft bearing (1) from the front
case (2) with suitable snap-ring pliers.
2. Transfer the retaining ring to the new bearing if
necessary and install the bearing into the front
case.

3. Using Bearing Installer 6436 (2) and Universal
Handle C-4171 (3), remove front output shaft bear-
ing.
4. Start front output shaft bearing in case. Then seat
bearing with Universal Handle C-4171 and Bearing
Installer 6953.
5. Install front output shaft bearing retaining ring.
6. Remove input gear pilot bearing by inserting a suit-
ably sized drift (1) into the splined end of the input
gear (2) and driving the bearing out with the drift
andahammer.
7. Install new pilot bearing with Bearing Installer 8684.

8. Remove the front output shaft rear bearing with the
screw and jaws from Remover L-4454 (2) and Cup
8148 (3).
9. Install new bearing with Universal Handle C-4171
(1) and Bushing Installer 5066 (3).

10. The bearing bore is chamfered (1) at the top.
Install the bearing so it is flush with the lower
edge of this chamfer.
11. Remove the rear output shaft bearing from the
rear case using Bearing Installer 8684 (2) and
Universal Handle C-4171 (3).
12. Install the rear output shaft bearing into the rear
case (1) using Bearing Installer 6953 (2) and Uni-
versal Handle C-4171 (3).

INPUT AND PLANETARY GEAR
1. Lubricate gears (3, 4) and thrust washers (5) with
recommended transmission fluid.
2. Install first thrust washer (5) in low range gear (3).
Be sure washer tabs are properly aligned in gear
notches.
3. Install input gear (3) in low range gear (4). Be sure
input gear is fully seated.
4. Install remaining thrust washer (5) in low range
gear (4) and on top of input gear (3). Be sure
washer tabs are properly aligned in gear notches.
5. Install retainer (2) on input gear and install snap-
ring (1).
6. Align and install low range/input gear assembly (2)
in front case (1). Be sure low range gear pinions
are engaged in annulus gear and that input gear
shaft is fully seated in front bearing.
7. Install snap-ring (2) to hold input/low range gear (1)
into front bearing.
8. Install a new input gear seal using Seal Installer
8841 and Universal Handle C-4171.

SHIFT FORKS AND MAINSHAFT
1. Lubricate mainshaft splines with recommended
transmission fluid.
2. Install the mode hub (1) onto the output shaft.
3. Install the mode hub retaining ring (2) onto the out-
put shaft (1).
4. Install the sprocket hub (2) onto the output shaft
(1).

5. Install the clutch gear (2) onto the output shaft (1).
6. Install the drive sprocket (2) onto the output shaft
(1).
7. Install the drive sprocket (3) thrust washer (2) onto
the output shaft (1).

8. Install the drive sprocket retaining ring (2) onto the
output shaft (1).
9. Lubricate sector shaft with transmission fluid and
install shift sector (1) in case. Position slot in sector
so it will be aligned with shift fork pin when shift
forks are installed.
10. Install the shift sector support (1). Tighten the sec-
tor support to 27-42 Nꞏm (20-30 ft.lbs.).

11. Assemble and install range fork (2) and hub (1).
Be sure hub is properly seated in low range gear
and engaged to the input gear.
12. Align and insert range fork pin in shift sector slot.
13. Install the range fork retaining ring.
14. Install mode fork (1) and shift rail (2) onto the
mode sleeve (3).
15. Install the mode fork, sleeve, and shift rail into the
transfer case.
16. Install mainshaft (2) into the transfer case (1).
Guide mainshaft through the mode and range
sleeves and into the input gear.