DODGE RAM SRT-10 2006 Service Repair Manual

INPUT AND PLANETARY GEAR
1. Lubricate gears and thrust washers (5) with recom-
mended transmission fluid.
2. Install first thrust washer in low range gear (4). 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.
NOTE: Replace the mode hub retainer if the legs
were distorted during removal.
2. Install the mode hub retainer (1) onto the mode
hub (2).
3. Install the mode hub (2) and mode hub retainer
onto the differential assembly (1). Make sure the
retainer is fully seated onto the differential.
4. Install the differential assembly (1) onto the main-
shaft (2).

5. Install the differential snap-ring (1).
6. Install the intermediate clutch shaft (1).
7. Install the clutch shaft thrust ring (1).

8. Install clutch shaft (2) snap-ring (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 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 shift rail (1) into the range fork assem-
bly (2) and the front case.
14. Install the mainshaft and differential assembly (2)
into the input gear and transfer case (1).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Install the front output shaft into the front output
shaft bearing.
2. Install the front output shaft snap-ring (2) onto the
output shaft (1).
3. Install the new front output shaft seal with Installer
MB991168A

4. Install new o-ring (1) on detent plug (2).
NOTE: Shift the transfer case to the same range/
mode position it was in when the shift motor was
removed prior to installing the shift detent compo-
nents.
5. Install detent plunger (4), spring (3), and plug (2).
Tighten the plug to 16-25 Nꞏm (12-18 ft. lbs.).
6. Install the new front output shaft seal slinger (1)
with Installer 8840 (2). Install the slinger onto the
shaft until the tool contacts the front of the output
shaft.

7. Install the front sprocket (1), rear sprocket (3), and
chain (2) as an assembly.
8. Lower the front sprocket, rear sprocket, and chain
over the front and rear output shafts simultaneously
until fully seated on both splines.
9. Install the rear output shaft retaining ring (2) onto
the output shaft (1).
10. Install the front sprocket (1) retaining ring (2).

11. Inspect mode fork assembly (1). Replace pads if
necessary. Also check springs and slider bracket.
Replace worn or damaged components.
12. Install the mode fork (2) and sleeve (3) over the
shift rail (1) and mainshaft.
13. Install spring (2) onto the shift rail (1).

14. 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, if
necessary.
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 and oil pump
assembly (1).
5. Install rear output bearing snap-ring (3) to output
shaft (1).

6. Install 4-5 rear case-to front case bolts (3) to hold
rear case (1) 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.
7. Apply Mopar
Lock ’n Seal Adhesive to remainder
of rear case-to-front case bolt threads and install
bolts. Tighten bolts to 25-28 Nꞏm (18-21 ft. lbs.),
SEAL BOOT AND SHIFT MOTOR ASSEMBLY
1. Install a new seal boot clamp onto the seal boot.
2. Install the seal boot (2) and clamp onto the slinger
(2) hub and tighten the clamp with Crimp Tool
C-4975-A.
3. Position the shift motor and mode sensor assembly
onto the transfer case.
4. Install the bolts (3) to hold the shift motor and
mode sensor assembly (2) to the transfer case (1).
Tighten the bolts to 16-25 Nꞏm (12-18 ft. lbs.).