Transmission DODGE RAM SRT-10 2006 Service Manual Online

BLOCK-ENGINE
DESCRIPTION
The cylinder block is made of a sand-cast aluminum alloy. The cylinder block has interference-fit cast iron cylinder
liners. The cylinder liners are thermally installed during block manufacturing; they are not serviceable items.
Six iron main bearing caps use four bolts per cap; two vertical and two horizontal. A crankshaft oil scraper is
attached to the main bearing caps via extended main bearing cap bolts and nuts.
STANDARD PROCEDURE - CYLINDER BORE HONING
Before honing, stuff plenty of clean shop towels under
the bores and over the crankshaft to keep abrasive
materials from entering the crankshaft area.
1. Used carefully, the Cylinder Bore Sizing Hone
C-823, equipped with 220 grit stones, is the best
tool for this job. In addition to deglazing, it will
reduce taper and out-of-round, as well as removing
light scuffing, scoring and scratches. Usually, a few
strokes will clean up a bore and maintain the
required limits.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
2. Deglazing of the cylinder walls may be done if the
cylinder bore is straight and round. Use a cylinder
surfacing hone, Honing Tool C-3501, equipped with
280 grit stones (C-3501-3810). about 20-60
strokes, depending on the bore condition, will be
sufficient to provide a satisfactory surface. Using
honing oil C-3501-3880, or a light honing oil, avail-
able from major oil distributors.
CAUTION: DO NOT use engine or transmission oil, mineral spirits, or kerosene.
3. Honing should be done by moving the hone up and down fast enough to get a crosshatch pattern. The hone
marks should INTERSECT at 50° to 60° for proper seating of rings.
4. A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper crosshatch angle.
The number of up and down strokes per minute can be regulated to get the desired 50° to 60° angle. Faster up
and down strokes increase the crosshatch angle.
5. After honing, it is necessary that the block be cleaned to remove all traces of abrasive. Use a brush to wash
parts with a solution of hot water and detergent. Dry parts thoroughly. Usea clean, white, lint-free cloth to check
that the bore is clean. Oil the bores after cleaning to prevent rusting.
CLEANING
CAUTION: Remove all gasket material from cylinder block using a plastic gasket scraper and MoparBrake
Parts Cleaner or the equivalent, this will prevent damage to the cylinder block.
1. When cleaning the cylinder block, remove the oil gallery plugs at the front and rear of the block.
2. Spray compressed air into all oil gallery passages to ensure they are clear of blockage.
3. Use a wooden or plastic scraper and MOPAR
Brake Parts Cleaner or the equivalent to remove the old gasket.
4. Clean the oil passages in the crankshaft with a brush.

SEAL-OIL-REAR-CRANK AND RETAINER
REMOVAL
1. Remove transmission (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL - REMOVAL).
2. Remove clutch and flywheel (Refer to 6 - CLUTCH/
CLUTCH DISC - REMOVAL).
NOTE: The oil seal and retainer are serviced as an
assembly.
3. Remove the seal retainer bolts from cylinder block
and oil pan.
4. Remove the oil seal and retainer (1) assembly.
INSTALLATION
1. Clean the engine block and retainer. Make sure
surfaces are clean and free of oil.
2. Install Special Tool 9060 (1) (seal guide) onto end
of crankshaft. Align hole in tool with dowel pin on
crankshaft.

3. Carefully position retainer/oil seal (1) to block.
Tighten the retainer bolts to 11 Nꞏm (95 in. lbs.).
4. Install flywheel and clutch (Refer to 6 - CLUTCH/
CLUTCH DISC - INSTALLATION).
5. Install transmission (Refer to 21 - TRANSMISSION/
TRANSAXLE/MANUAL - INSTALLATION).

BEARING-CRANKSHAFT PILOT
REMOVAL
1. Remove transmission (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL - REMOVAL).
2. Remove clutch and flywheel (Refer to 6 - CLUTCH/
CLUTCH DISC - REMOVAL).
3. Using Special Tools 8990 (1) and C-3752 (2),
remove pilot bearing from crankshaft.
INSTALLATION
NOTE: New pilot bearing has special grease
packed into bearing. Do not wash grease from
bearing. Install bearing with part number markings
(1) facing out.

1. Install pilot bearing with Special Tools 9058 (1) and
C-4171 (2).
2. Install flywheel and clutch (Refer to 6 - CLUTCH/
CLUTCH DISC - INSTALLATION).
3. Install transmission (Refer to 21 - TRANSMISSION/
TRANSAXLE/MANUAL - INSTALLATION).

PIPE EXHAUST
REMOVAL
3.7L/4.7L/5.7L ENGINE
1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Remove exhaust pipe to manifold bolts and nuts.
4. Remove the clamp nuts.
5. Remove the exhaust pipe.
5.9L DIESEL
1. Disconnect the battery negative cables.
2. Raise and support the vehicle on a hoist.
3. Saturate the bolts and nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
4. Remove the exhaust pipe-to-extension pipe clamp.
Separate the exhaust pipe and extension pipe.
5. Remove the exhaust pipe-to-turbocharger elbow
clamp and discard.
6. Remove the exhaust pipe from the transmission
support.
8.3L ENGINE
1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
3. Remove clamp nuts.
4. Remove exhaust pipe isolators.
5. Rotate the exhaust pipes to remove from the
muffle.

INSPECTION
Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with original equipment
parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust
noise levels.
INSTALLATION
3.7L/4.7L/5.7L ENGINE
1. Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25
mm (1.0 in.) is required.
2. Position the exhaust pipe to manifold. Install the bolts and nuts. Tighten the nuts to 31 Nꞏm (23 ft. lbs.) torque.
3. Tighten the clamp nuts to 54 Nꞏm (40 ft. lbs.) torque.
4. Lower the vehicle.
5. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the
alignment, if needed.
5.9L DIESEL
1. Install the exhaust pipe into the transmission sup-
port and onto the turbocharger flange.
2. Install a New exhaust pipe-to-turbocharger elbow
clamp and tighten to 11 Nꞏm (100 in. lbs.) torque.
3. Install the extension pipe and clamp to the exhaust
pipe using a new clamp and tighten the clamp nuts
to 54 Nꞏm (40 ft. lbs.) torque.
4. Check the exhaust system for contact with the
body panels. A minimum of 25 mm (1.0 in.) is
required between the exhaust system components
and body/frame parts. Make the necessary adjust-
ments, if needed.
5. Lower the vehicle.
6. Connect the battery negative cables.
7. Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.

DIAGNOSIS AND TESTING
CHARGE AIR COOLER SYSTEM - LEAKS
Low turbocharger boost pressure and low engine per-
formance can be caused by leaks in the charge air
cooler or plumbing. Fuel staining on the exhaust man-
ifold can also be an indication that there are leaks in
the air system. The followingprocedure outlines how
to check for leaks in the charge air cooler system.
This procedure can also be used to check for leaks in
the wastegate signal line or the wastegate canister.
1. Loosen clamp and remove air inlet hose from tur-
bocharger.
2. Insert Special Tool 9022 Adapter into the turbo-
charger inlet. Tighten tool clamp to 8 Nꞏm (72 in.
lbs.).
CAUTION: Do not apply more than 138 kPa (20
psi) air pressure to the charge air cooler system,
severe damage to the charge air cooler system
may occur.
3. Connect a regulated air supply to air fitting on Tool
9022 Adapter. Set air pressure to a Maximum of
138 kPa (20 psi).
4. Using soapy water check the rubber sleeves, charge air cooler and intakemanifold for leaks.
5. Using soapy water check for leaks at the wastegate signal line, wastegate canister and wastegate command
valve.
REMOVAL
WARNING: IF THE ENGINE WAS JUST TURNED
OFF, THE AIR INTAKE SYSTEM TUBES MAY BE
HOT.
1. Disconnect the battery negative cables.
2. Discharge the A/C system (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE) and remove the A/C condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - REMOVAL) (if A/C
equipped).
3. Remove the transmission auxiliary cooler (Refer to
7 - COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
4. Remove intake air tubing from the charge air
cooler.
5. Remove the charge air cooler bolts. Pivot the
charge air cooler forward and up to remove.

2. Install the air intake system tubes to the charge air
cooler. With the clamps in position, tighten the
clamps to 11 Nꞏm (95 in. lbs.) torque.
3. Install the transmission auxiliary cooler (if
equipped) (Refer to 7 - COOLING/TRANSMIS-
SION/TRANS COOLER - INSTALLATION).
4. Install the A/C condenser (if A/C equipped) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C CONDENSER - INSTALLATION).
Recharge A/C system (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE).
5. Connect the battery negative cables.
6. Start engine and check for boost system leaks.

FRAME & BUMPERS
TABLE OF CONTENTS
page page
FRAMES & BUMPERS
SPECIFICATIONS
TORQUE .................................... 2
FRONT AIR DAM
REMOVAL ..................................... 3
INSTALLATION ................................ 3
FRONT BUMPER
REMOVAL ..................................... 4
INSTALLATION ................................ 4
FRONT FASCIA
REMOVAL ..................................... 5
INSTALLATION ................................ 6
REAR BUMPER
REMOVAL ..................................... 7
INSTALLATION ................................ 8
FASCIA-FRONT SRT-10
REMOVAL ..................................... 9
INSTALLATION ................................ 11
FASCIA-REAR SRT-10
REMOVAL .................................... 14
INSTALLATION ............................... 15
FRAME
WARNING
WARNINGS ................................ 17
STANDARD PROCEDURE
HYDROFORM FENDER RAIL REPAIR ........ 18REAR FRAME H-SECTION REPLACEMENT . . . 27
SPECIFICATIONS
WELD PROCESS ........................... 33
FRAME DIMENSIONS ....................... 34
TORQUE ................................... 45
FRONT CROSSMEMBER
REMOVAL .................................... 46
INSTALLATION ............................... 48
FRONT SKID PLATE
REMOVAL .................................... 50
INSTALLATION ............................... 51
FRONT TOW HOOK ASSEMBLY
REMOVAL .................................... 52
INSTALLATION ............................... 53
TRANSMISSION CROSSMEMBER
REMOVAL .................................... 54
INSTALLATION ............................... 56
TRAILER HITCH
REMOVAL .................................... 58
INSTALLATION ............................... 60
TRANSFER CASE SKID PLATE
REMOVAL .................................... 62
INSTALLATION ............................... 63