DODGE RAM SRT-10 2006 Service Repair Manual

3. Remove the mode hub (2) from the mainshaft (1).
4. Remove the drive sprocket drive hub (2) from the
mainshaft.

INPUT AND PLANETARY GEAR
1. Remove input gear seal with suitable screw and
slide hammer.
2. Remove input gear 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.
4. Remove snap-ring (2) that retains input gear in the
low range gear (1).

5. Remove retainer (2).
6. Remove front thrust plate (2) from the input gear
(1).
7. Remove input gear (1) from the low range plane-
tary (2).

8. Remove bottom tabbed thrust washer (2) from low
range planetary (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 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 be smoothed with 300-400 grit emery cloth
if necessary.
Examine the carrier body and pinion gears for wear or damage. Check the pinion gear thrust washers on the pinon
pins for damage. The carrier will have to be replaced as an assembly if the body, pinion pins, or pinion gears are
damaged.
Check the lock ring and both thrust washers for wear or cracks. Replace themif necessary. Also replace the lock
retaining ring 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

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). The mode and
range fork pads are serviceable and can be replaced
if necessary.
Check both of the sleeves for wear or damage, espe-
cially on the interior teeth. Replace the sleeves if wear
or damage is evident.
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 (1). 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 (2)

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 snap-ring from the
front case half with suitable snap-ring pliers.
2. Remove the input shaft bearing from the front case
half with Bearing Installer 6953 (3) and Universal
Handle C-4171 (2).
3. Install the input shaft bearing into the front case
half with Bearing Cup Installer 8151 (3) inverted on
Universal Handle C-4171 (2).
4. Install the input shaft bearing snap-ring into the
front case half with suitable snap-ring pliers.

5. Remove the front output shaft front bearing snap-
ring from the front case half.
6. Using Bearing Installer 6953 (3) and Universal
Handle C-4171 (2), remove the front output shaft
front bearing.
7. Start front output shaft front bearing in front case
(1). Then seat bearing with Seal Installer 8891 (2).
8. Install front output shaft bearing retaining ring.

9. Remove input gear pilot bearing by inserting a suit-
ably sized drift into the splined end of the input
gear (2) and driving the bearing out with the drift
(1) and a hammer.
10. Install new pilot bearing with Bearing Installer
9035.
11. Remove the front output shaft rear bearing with
the screw and jaws from Remover L-4454 (2) and
Cup8148(3).

12. Install new bearing with Universal Handle C-4171
(2) and Bearing Installer 8128 (3).
13. The bearing bore is chamfered at the top. Install
the bearing (1) so it is flush with the lower edge of
this chamfer (2).
14. Remove seal from oil pump with suitable pry tool.
15. Install new seal in oil pump (3) with Seal Installer
7888 (2).