DODGE RAM SRT-10 2006 Service Repair Manual

FLUID
STANDARD PROCEDURE - FLUID DRAIN AND REFILL
The fill (2) and drain (3) plugs are both in the rear
case.
1. Raise vehicle.
2. Position drain pan under transfer case.
NOTE: It may be necessary to remove the exhaust
y-pipe at the exhaust manifold to properly access
the fill and drain plugs. Lowering the exhaust will
allow the plugs to be accessed for torquing during
installation. (Refer to 11 - EXHAUST SYSTEM/EX-
HAUST PIPE - REMOVAL)
3. Remove drain and fill plugs and drain lubricant
completely.
4. Install drain plug. Tighten plug to 20-34 Nꞏm (15-25
ft. lbs.).
5. Remove drain pan.
6. Fill transfer case to bottom edge of fill plug opening with Mopar
ATF +4, Automatic Transmission fluid.
7. Install and tighten fill plug to 20-34 Nꞏm (15-25 ft. lbs.).
8. Install the exhaust y-pipe to the exhaust manifold, if removed. (Refer to 11 - EXHAUST SYSTEM/EXHAUST
PIPE - INSTALLATION)
9. Wipe any excess fluid that mayhave spilled onto the exhaust.
10. Lower vehicle.

SEAL-FRONT OUTPUT SHAFT
REMOVAL
1. Remove the front propeller shaft (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL).
2. Remove the front propeller shaft seal boot (1)
retaining clamp (2).
3. Remove the front propeller shaft seal boot (1).
4. Remove the front output shaft seal slinger (1) by
bending (2) the slinger ears away from the transfer
case.

5. Using a suitable pry tool (2), remove the slinger (1)
from the output shaft using care not to damage the
shaft.
6. Using a screw and a slide hammer, remove the
front output shaft seal.
INSTALLATION
1. Install the new front output shaft seal with Seal Installer MB991168A.
2. Install the front output shaft seal slinger with Oil Slinger Installer 8840. Install the slinger onto the shaft until the
tool contacts the rear of the output shaft.
3. Install a new seal boot clamp onto the seal boot.
4. Install the seal boot and clamp onto the slinger hub and tighten the clampwith Crimp Tool C-4975-A.
5. Install front propeller shaft (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPELLER
SHAFT - INSTALLATION).

SENSOR-MODE
DESCRIPTION
The transfer case mode sensor (1) is an electronic
device whose output can be interpreted to indicate the
shift motor shaft’s rotary position. The sensor consists
of a magnetic ring and four Hall Effect Transistors to
create a 4 channel digital device (non-contacting)
whose output converts the motor shaft position into a
coded signal. The TCCM must supply 5VDC (+/- 0.5v)
to the sensor and monitor the shift motor position. The
four channels are denoted A, B, C, and D. The sensor
is mechanically linked to the shaft of the cam which
causes the transfer case shifting. The mode sensor
draws less than 53 mA.
OPERATION
During normal vehicle operation, the Transfer Case Control Module (TCCM)monitors the mode sensor outputs at
least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor
is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined.
Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector
versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the
sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears posi-
tions can also be referred as the transfer case’s coarse position. These coarse positions come into play during shift
attempts.
SECTOR ANGLES vs. TRANSFER CASE POSITION
Shaft Angle (Degrees) Transfer Case Position
+40 4LO
+20 N
0 2WD/AWD
-20 4HI
MODE SENSOR CHANNEL STATES
Transfer Case
Angle (degrees)Sensor Channel A Sensor Channel B Sensor Channel C Sensor Channel D
Between Gears H H L H
+40 (4LO) H H L L
Between Gears H H L H
Between Gears H L L H
+20 (NEUTRAL) H L L L
Between Gears H L L H
Between Gears H L H H

Transfer Case
Angle (degrees)Sensor Channel A Sensor Channel B Sensor Channel C Sensor Channel D
0 (2WD/AWD) H L H L
Between Gears H L H H
Between Gears L L H H
-20 (4HI) L L H L
Between Gears L L H H
Between Gears L H H H

SWITCH-SELECTOR
DESCRIPTION
The selector switch assembly is mounted in the left
side of the vehicle’s Instrument Panel (IP) and con-
sists of a rotary knob connected to a resistive network
for the mode and range shift selections. Also located
in this assembly is a recessed, normally open momen-
tary switch for making shifts into and out of transfer
case NEUTRAL. A pen, or similar instrument, is used
to make a NEUTRAL shift selection, thus reducing the
likelihood of an inadvertent shift request.
The selector switch also contains four light emitting
diode’s (LED’s) to indicate the transfer case position
and whether a shift is in progress.
OPERATION
As the position of the selector switchvaries, the resistance between the Mode Sensor supply voltage pin and the
Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module
(TCCM) are provided that interpret the selector switch resistance as giveninthetablebelow:SELECTORSWITCH
INTERPRETATION
SELECTOR SWITCH INTERPRETATION
Step Resistance Range (ohms) Required Interpretation
A <200 Shorted
B 400-700 NEUTRAL
C 1050-1450 4LO
D 1850-2300 4HI
E 3050-5950 2WD (Default)
F 9.5-12.5K In between positions
G>15.5KOpen
For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the
TCCM may interpret the resistance as:
either of the neighboring valid positions.
as an invalid fault position.
For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the
resistance as:
the 2WD position.
an invalid fault position.
a valid in-between position.
For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM
may interpret the resistance as:
a valid in-between position.
an invalid fault position.

For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM
may interpret the resistance as:
the T-Case NEUTRAL position.
an invalid fault position.
The LED’s in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition
or state.
A solidly illuminated LED indicates asuccessfully completed shift and the current operating mode of the trans-
fer case. While a shift has been requested but not yet completed, the LED forthe desired transfer case posi-
tion is flashed.
A flashing operating mode LED for the desired gear indicates that a shift tothat position has been requested,
but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the
transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined
(other than a diagnostic failure that would prevent this shift) elsewhere(Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/TRANSFER CASE CONTROL MODULE - OPERATION) is not met. Note that
this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is
changed, or if diagnostic routines no longer allow the requested shift.
If the driver attempts to make a shift into transfer case NEUTRAL, and any ofthe driver controllable conditions
are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button
is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator
controllable conditions are not being met. All of the LED’s except the Neutral will flash if any of the operator
controllable conditions for shifting are not met while the Neutral buttonis depressed. This
toggletype of fea-
ture is necessary because the TCCM would interpret another request immediately after the shift into transfer
case NEUTRAL has completed.
No LED’s illuminated indicate a fault in the transfer case control system.

MOTOR-SHIFT
DESCRIPTION
The shift motor (1) consists of a permanent magnet
D.C. motor with gear reduction to convert a high
speed-low torque device into a low speed-high torque
device. The output of the device is coupled to a shaft
which internally moves the mode and range forks that
change the transfer case operating ranges. The motor
is rated at 25 amps maximum at (23° C (72° F) with
10 volts at the motor leads.
OPERATION
The transfer case shift motor responds to the Transfer Case Control Module(TCCM) commands to move the trans-
fer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instru-
ment panel mounted selector switch.
REMOVAL
NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will
be installed, it will be necessary to shift the transfer case to the 2WD/AWDposition prior to motor removal.
1. Raise the vehicle on a suitable hoist.
2. Disengage the wiring connectors from the shift motor and mode sensor.
3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case.
4. Separate the shift motor and mode sensor assembly from the transfer case.
INSTALLATION
1. Verify that the shift sector o-ring is clean and properly positioned over the shift sector and against the transfer
case.
NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to
manually shift the transfer case if the shift motor and sector shaft are notaligned.
2. Position the shift motor and mode sensor assembly onto the transfer case.
3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nꞏm (12-18 ft.lbs.).
CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar
Lock & Seal or Loctite™ 242 to replenish the lock patch material originallyfound on the bolts
4. Engage the wiring connectors to the shift motor and mode sensor.
5. Refill the transfer case as necessary.

6. Lower vehicle and verify transfer case operation.

ASSEMBLY-SHIFT MOTOR/MODE SENSOR
DESCRIPTION
The shift motor (1) consists of a permanent magnet
D.C. motor with gear reduction to convert a high
speed-low torque device into a low speed-high torque
device. The output of the device is coupled to a shaft
which internally moves the mode and range forks that
change the transfer case operating ranges. The motor
is rated at 25 amps maximum at (23° C (72° F) with
10 volts at the motor leads.
OPERATION
The transfer case shift motor responds to the Transfer Case Control Module(TCCM) commands to move the trans-
fer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instru-
ment panel mounted selector switch.