DODGE RAM SRT-10 2006 Service Repair Manual

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TRANSFER CASE - NV244 GENII - SERVICE
INFORMATION
DESCRIPTION ............................. 1701
OPERATION ............................... 1701
DIAGNOSIS AND TESTING
TRANSFER CASE - NV244 ................ 1702
REMOVAL ................................. 1703
DISASSEMBLY ............................. 1703
CLEANING ................................. 1715
INSPECTION ............................... 1715
ASSEMBLY . ............................... 1718
INSTALLATION ............................. 1730
SPECIFICATIONS
TRANSFER CASE - NV244 GENII .......... 1730
SPECIAL TOOLS
TRANSFER CASE - NV244 GENII .......... 1731
SEAL-EXTENSION HOUSING
REMOVAL ................................. 1733INSTALLATION ............................. 1733
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL ................................... 1734
SEAL-FRONT OUTPUT SHAFT
REMOVAL ................................. 1735
INSTALLATION ............................. 1736
SENSOR-MODE
DESCRIPTION ............................. 1737
OPERATION ............................... 1737
SWITCH-TRANSFER CASE SELECTOR
DESCRIPTION ............................. 1739
OPERATION ............................... 1739
MOTOR-SHIFT
DESCRIPTION ............................. 1741
OPERATION ............................... 1741
REMOVAL ................................. 1741
INSTALLATION ............................. 1741

TRANSFER CASE - NV244 GENII - SERVICE INFORMATION
DESCRIPTION
The NV244 GENII is an electronically controlled full and part-time transfer case with no two wheel drive operation.
A differential in the transfer case is used to control torque transfer to the front and rear axles. A low range gear
reduction system provides increased low speed torque capability for off road operation. The low range provides a
2.72:1 reduction ratio.
The geartrain is mounted in two aluminum case halves attached with bolts. The mainshaft front and rear bearings
are mounted in aluminum retainer housings bolted to the case halves.
OPERATING RANGES
NV244 GENII operating ranges are:
AWD (All-Wheel Drive).
4LOCK (Part-time).
4LO.
NEUTRAL.
The AWD mode can be used at any time and on any road surface.
The 4LOCK (Part-time) and 4LO ranges are for off road use only. The only timetheserangescanbeusediswhen
the road surface is covered with snow, ice, or other loose slippery material.
SHIFT MECHANISM
Operating ranges are selected with a dash mounted shift selector switch. The shift selector switch provides a input
to the Front Control Module (FCM) to indicate the driver’s desire to changeoperating ranges. The FCM uses this
input, along with the input from the transfer case mounted mode sensor and information from the vehicle’s bus, to
determine if a shift is permitted. If the FCM decides the shift is permitted, the FCM controls the shift motor, mounted
to the exterior of the transfer case, to perform the shift.
IDENTIFICATION
A circular ID (1) tag is attached to the rear case of
each transfer case. The ID tag provides the transfer
case model number, assembly number, serial number,
and low range ratio.
The transfer case serial number also represents the
date of build.
OPERATION
The input gear is splined to the transmission output shaft. The input gear drives the mainshaft through the planetary
assembly and range sleeve. The front output shaft is operated by a drive chain that connects the shaft to a drive
sprocket on the mainshaft. The drive sprocket is splined to a differentialassembly. Depending on the position of the
mode fork and sleeve, the front output shaft is driven directly by the mainshaft or through the differential. The mode
fork operates the mode sleeve and hub. The sleeve and hub are not equipped with a synchronizer mechanism for
shifting.

DIAGNOSIS AND TESTING
TRANSFER CASE - NV244
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
Transfer case difficult to shift or will
not shift into desired range.1) Transfer case electronically
controlled shift system malfunction.1) Verify proper operation per the
appropriate diagnostic manual.
2) Insufficient or incorrect lubricant. 2) Drain and refill transfer casewith
the correct quantity of Mopar
AT F
+4, Automatic Transmission Fluid.
3) Internal transfer case
components binding, worn, or
damaged.3) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.1) Insufficient or incorrect lubricant. 1) Drain and refill transfer casewith
the correct quantity of Mopar
AT F
+4, Automatic Transmission Fluid.
2) Internal transfer case
components binding, worn, or
damaged.2) Repair or replace components as
necessary.
Transfer case noisy while in, or
jumps out of, 4LO.1) Transfer case not completely
engaged in 4LO position.1) While rolling 2-3 MPH and the
transmission in NEUTRAL, or the
clutch depressed on vehicles
equipped with a manual
transmission, shift the transfer case
to the AWD or 4LOCK position, and
then back into the 4LO position.
2) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.2) Repair or replace components as
necessary.
3) Low range gear worn or
damaged.3) Repair or replace components as
necessary.
Lubricant leaking from transfer case
seals or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.3) Replace suspect seal.
Transfer case will not shift through
4LOCK (Part-time) range.1) Incomplete shift due to drivetrain
torque load.1)Driveinastraightlineand
momentarily release the accelerator
pedal to complete the shift.
2) Incorrect tire pressure. 2) Correct tire pressure as
necessary.
3) Excessive tire wear. 3) Correct tire condition as
necessary.
4) Excessive vehicle loading. 4) Correct as necessary.

REMOVAL
1. Shift transfer case into AWD.
2. Raise vehicle.
3. Drain transfer case lubricant.
4. Mark front and rear propeller shafts for alignment
reference.
5. Support transmission with jack stand.
6. Remove the transfer case skid plate, if equipped.
7. Disconnect front and rear propeller shafts at trans-
fer case.
8. Disconnect transfer case shift motor and mode
sensor wire connectors (3).
9. Disconnect transfer case vent hose.
10. Support transfer case with transmission jack.
11. Secure transfer case to jack with chains.
12. Remove nuts attaching transfer case to transmission (1).
13. Pull transfer case and jack rearward to disengage transfer case.
14. Remove transfer case from under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubricant remaining in
case.
SHIFT MOTOR ASSEMBLY AND FRONT OUTPUT SHAFT SEAL
1. Remove the bolts (3) which hold the shift motor
and mode sensor assembly (2) to the transfer case
(1).
2. Remove the shift motor and mode sensor assem-
bly from the transfer case.

3. Remove the front propeller shaft seal boot (1)
retaining clamp (2).
4. Remove the front propeller shaft seal boot (1).
5. Remove the front output shaft seal slinger (1) by
bending (2) the slinger away from the transfer
case.
6. Using a suitable pry tool, remove the slinger from
the output shaft using care not to damage the
shaft.
7. Using a screw and a slide hammer, remove the
front output shaft seal.

REAR EXTENSION
1. Remove rear extension housing (1) bolts.
2. Remove rear extension housing (1). Tap extension
once or twice with a plastic mallet to break sealer
bead and loosen it.
3. Remove output shaft bearing (2) retaining ring (3)
with heavy duty snap-ring pliers.

OIL PUMP AND REAR CASE
1. Remove rear case (1) -to-front case (2) bolts (3).
2. Loosen rear case (1) with pry tool to break sealer
bead. Insert tool in slot (3) at each end of case.
3. Unseat rear case from alignment dowels.
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.
4. Remove rear case (1) and oil pump assembly from
front case (2).
5. Remove the oil pump pickup tube.

FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Remove shift rail (1) spring (2).
2. Remove front sprocket (1) retaining ring (2).
3. Remove the mode fork (2) and sleeve (3) from the
shift rail (1) and mainshaft.

4. Remove the rear output shaft retaining ring (2)
from the output shaft (1).
5. Pull front sprocket (1), rear sprocket (3), and chain
(2) outward simultaneously.
6. Remove front sprocket, rear sprocket, and chain as
an assembly.
SHIFT FORKS AND MAINSHAFT
1. Loosen detent plug (2).
2. Remove detent plug (2), spring (3), and plunger
(4). Note that the plug has an O-ring seal. Remove
and discard this seal.

3. Remove the front output shaft (1) snap-ring (2).
4. Remove front output shaft from bearing in case.
5. Remove the mainshaft and differential assembly (2)
from the input gear and transfer case (1).
6. Remove the shift rail (1) from the range fork
assembly (2) and the front case.