DODGE RAM SRT-10 2006 Service Repair Manual

6. Install snap-ring (2).
7. 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.
8. Install snap-ring (2) to hold input/low range gear (1)
into front bearing.
9. Install a new input gear oil seal with Seal Installer
9036 and Universal Handle C-4171.

SHIFT FORKS AND MAINSHAFT
1. Lubricate mainshaft splines with recommended
transmission fluid.
2. Coat the interior of the drive sprocket hub with
ATF+4 and install the drive sprocket drive hub (2)
onto the mainshaft (1).
3. Install the mode hub (2) onto the mainshaft (1).

4. Install the mode hub (2) retaining ring (3) onto the
mainshaft (1).
5. Install the clutch gear (2) onto the output shaft (1).
Verify that the pointed ends of the clutch gear teeth
are pointing to the front of the mainshaft.
6. 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.
7. Apply Loctite™ 242, or equivalent, to the threads of
the sector support to replenish the factory applied
patch. Install the shift sector support. Tighten the
sector support with Socket 9033 to 27-34 Nꞏm
(20-25 ft.lbs.).

8. 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.
9. Align and insert range fork pin in shift sector slot.
10. Install mode fork and shift rail onto the mode
sleeve.
11. Install the mode fork (2), sleeve (1), and shift rail
(2) into the transfer case.
12. Install new o-ring (1) on detent plug (2).

13. Install detent plunger (4), spring (3), and plug (2).
Tighten the plug to 16-25 Nꞏm (12-18 ft. lbs.).
14. Position the shift motor and mode sensor assem-
bly (2) onto the transfer case (1).
15. 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.).

16. Install mainshaft (2) into the transfer case (1).
Guide mainshaft through the mode and range
sleeves and into the input gear.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Install the front output shaft (2) into the front output
shaft front bearing.
2. Install the front output shaft bearing inner snap-ring
(2) onto the output shaft.
3. Install the new front output shaft seal with Seal
Installer MB991168A.

4. Insert front drive sprocket (3) in drive chain (2).
5. Install drive chain around rear drive sprocket.
6. Position rear drive sprocket over the output shaft
and lower the sprocket and chain assembly until
the front sprocket is positioned over the front out-
put shaft.
7. Align the splines in the sprockets to the splines on
the output shafts and install the sprockets onto the
output shafts.
8. Install front sprocket (2) retaining ring (3).
9. Install rear sprocket (2) retaining ring (3).

10. Insert magnet (1) in front case pocket (2).
REAR CASE
1. Install the oil pick-up tube and screen into the rear
case half.
2. 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 exces-
sive amount of sealer as excess will be displaced
into case interior.
3. Align mainshaft with the rear output shaft bearing
and align shift rail with bore in rear case. Then
install rear case (2). Verify that the case alignment
dowels correctly seat into their mating recesses.
4. Install 4-5 rear case (2) to front case (1) 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.
5. Tighten bolts to 27-34 Nꞏm (20-25 ft. lbs.).

6. Install rear output bearing inner snap-ring (3) to
output shaft (1).
OIL PUMP AND REAR EXTENSION
1. Install the oil pump (3) onto the output shaft (2).

2. Engage the oil pump pick-up tube (2) into the oil
pump (1). Verify that the pick-up tube o-ring is on
the tube and is correctly installed to the oil pump.
3. 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.
4. Install extension housing (2) onto the rear case half
(1).
5. Install rear extension bolts (2). Tighten the bolts to
27-34 Nꞏm (20-25 ft.lbs.).