DODGE RAM SRT-10 2006 Service Repair Manual

7. Install the drive sprocket (3) thrust washer (2) onto
the output shaft (1).
8. Install the drive sprocket (2) retaining ring (2) onto
the output shaft (1).
9. Lubricate sector shaft (1) with transmission fluid
and install shift sector in case. Position slot in sec-
torsoitwillbealignedwithshiftforkpinwhenshift
forks are installed.

10. Install the shift sector o-ring.
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 and shift rail onto the mode
sleeve.
15. Install the mode fork (2), sleeve (1), and shift rail
(2) into the transfer case.
16. Install mainshaft (2) into the transfer case front
housing (1). Guide mainshaft through the mode
and range sleeves and into the input gear.

17. Install new o-ring (1) on detent plug (2).
18. Install detent plunger (4), spring (3), and plug (2).
Tighten the plug to 16-25 Nꞏm (12-18 ft. lbs.).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Install the front output shaft (2) into the front output
shaft bearing.

2. Install the front output shaft retaining ring (2) onto
the output shaft (1).
3. Install the new front output shaft seal with Seal
Installer MB991168A.
4. Insert front sprocket (1) in drive chain (2).
5. Install drive chain (2) around mainshaft sprocket.
Then position front sprocket over front shaft.
6. Raise mainshaft about 2.54 cm (one inch) and seat
front sprocket on front output shaft.
7. If mainshaft and mode sleeve were unseated dur-
ing chain installation, align and reseat mainshaft in
input gear and hub.
8. Install front sprocket (1) retaining ring (2).

9. Install spring (2) and cup (1) on shift rail.
10. Insert magnet (1) in front case pocket (2).
OIL PUMP AND REAR CASE
Lubricate the oil pump components with transmission
fluid before installation. Prime the oil pickup tube by
pouring a little oil into the tube before installation.
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 inner
bearing race and will become mis-aligned if the
bolts are loosened. If the transfer case failure has
generated any debris which may have become
trapped in the oil pump. the rear case and oil
pump assembly MUST be replaced.
1. Install new o-ring in pickup tube inlet of oil pump.
2. Insert oil pickup tube into the oil pump.
3. Apply bead of Mopar
Gasket Maker, or equivalent,
to mating surface of front case. Keep sealer bead
width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess will be displaced into case
interior.
4. Align oil pump with mainshaft and align shift rail with bore in rear case.Then install rear case (1) and oil pump
assembly onto the front case (2).

5. Install 4-5 rear case (1)-to front case (2) bolts (3) to
hold rear case in position. Tighten bolts snug but
not to specified torque at this time.
CAUTION: Verify that shift rail, and case alignment
dowels are seated before installing any bolts.
Case could be cracked if shaft rail or dowels are
misaligned.
6. Apply Loctite™ 242 to remainder of rear case-to-
front case bolt threads and install bolts. Tighten
bolts to 20-27 Nꞏm (15-24 ft. lbs.).
7. Install rear output bearing (2) snap-ring (3) to out-
put shaft (1).
SEAL BOOT AND SHIFT MOTOR ASSEMBLY
1. Install the front output shaft seal slinger with Installer 8840. Install the slinger onto the shaft until the tool contacts
the rear of the output shaft.
2. Install a new seal boot clamp onto the seal boot.
3. Install the seal boot and clamp onto the slinger hub and tighten the clampwith Crimp Tool C-4975-A.
4. Position the shift motor and mode sensor assembly onto the transfer case.
5. Install the bolts to hold the shift motor and mode sensor assembly to the transfer case. Tighten the bolts to 16-25
Nꞏm (12-18 ft. lbs.).

REAR EXTENSION
1. Install new seal in rear extension housing seal with
Installer D-163 and Universal Handle C-4171..
2. Apply bead of Mopar
Gasket Maker, or equivalent,
to mating surface of rear extension housing. Keep
sealer bead width to maximum of 3/16 inch. Do not
use excessive amount of sealer as excess could
be displaced into output bearing.
3. Align and install rear extension (1) on the transfer
case (2).
4. Apply Mopar
Silicone Sealer to threads of rear
extension housing bolts. Then install and tighten
bolts to 16-24 Nꞏm (12-18 ft. lbs.) torque.
INSTALLATION
1. Mount transfer case on a transmission jack.
2. Secure transfer case to jack with chains.
3. Position transfer case under vehicle.
4. Align transfer case and transmission shafts and install transfer case onto the transmission.
5. Install and tighten transfer case attaching nuts to 27-34 Nꞏm (20-25 ft.lbs.) torque.
6. Connect the vent hose.
7. Connect the shift motor and mode sensor wiring connectors. Secure wire harness to clips on transfer case.
8. Align and connect the propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/FRONT
PROPELLER SHAFT - INSTALLATION) (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/REAR
PROPELLER SHAFT - INSTALLATION)
9. Fill transfer case with correct fluid. (Refer to 21 - TRANSMISSION/TRANSFER CASE/FLUID - STANDARD PRO-
CEDURE)
10. Install skid plate, if equipped.
11. Remove transmission jack and support stand.
12. Lower vehicle and verify transfer case shift operation.
SPECIFICATIONS
TRANSFER CASE - NV243
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Extension Housing 16-24 12-18 -
Bolt, Case Half 20-27 15-24 -
Screw, Oil Pump 12-16 8-12 -
Nuts, Mounting 30-41 20-30 -
Bolts, Shift Motor and
Mode Sensor Assembly16-24 12-18 -

SPECIAL TOOLS
TRANSFER CASE - NV243
Handle - C-4171
Installer, Seal - D-163
ToolSet-L-4518
Installer, Seal - MB991168A
Installer, Bushing - 5066
Installer, Bearing - 6953
Cup - 8148
Installer, Bearing - 8684
Installer - 8840

Installer, Seal - 8841

SEAL-EXTENSION HOUSING
REMOVAL
1. Raise and support vehicle.
2. Remove rear propeller shaft. (Referto 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPELLER
SHAFT - REMOVAL)
3. Using a suitable pry tool or slide-hammer mounted screw, remove the extension housing seal.
INSTALLATION
1. Clean fluid residue from sealing surface and
inspect for defects.
2. Using Seal Installer D-163 (2) and Universal Han-
dle C-4171 (1), install seal in extension housing.
3. Install propeller shaft. (Refer to 3 - DIFFERENTIAL
& DRIVELINE/PROPELLER SHAFT/PROPELLER
SHAFT - INSTALLATION)
4. Verify proper transfer case fluid level.
5. Lower vehicle.