2006 DODGE RAM SRT-10 oil

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. Remove output 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.
4. Remove rear case (1) and oil pump assembly from
front case (2).
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.
5. Remove the oil pump pickup tube.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Remove shift rail cup (3) and spring (2).
2. Remove front sprocket (1) retaining ring (2).

4. Remove input gear (1).
5. Remove rear tabbed thrust washer (2) from low
range gear (1).
CLEANING
Clean the transfer case parts with a standard parts cleaning solvent. Remove all traces of sealer from the cases
and retainers with a scraper and 3M™ all purpose cleaner. Use compressed air to remove solvent residue from oil
feed passages in the case halves, retainers, gears, and shafts.
INSPECTION
MAINSHAFT/SPROCKET/HUB INSPECTION
Inspect the splines on the hub and shaft and the teeth on the sprocket. Minornicks and scratches can be smoothed
with an oilstone. However, replace any part that is damaged.
Check the contact surfaces in the sprocket bore and on the mainshaft. Minornicks and scratches can be smoothed
with 320-400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe.

INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the input gear (6). Minor nicks can be dressed off with an oilstone but replace the gear if any
teeth are broken, cracked, or chipped. The bearing surface on the gear can besmoothedwith300-400gritemery
cloth if necessary.
Examine the planetary carrier body (1) and pinion gears for wear or damage.The carrier will have to be replaced
as an assembly if the body, pinion pins, or pinion gears are damaged.
Check the carrier lock ring (4) and both thrust washers (2, 3) for wear or cracks. Replace them if necessary. Also
replace the lock retaining ring if bent, distorted, or broken.
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork shift
rail (2). Minor nicks on the shift rail can be smoothed
with 320-400 grit emery cloth.
Input Gear and Carrier Components
1 - PLANETARY CARRIER 4 - CARRIER LOCK RING
2 - REAR THRUST WASHER 5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER 6 - INPUT GEAR

Inspect the shift fork wear pads (3, 4). The mode (2)
and range (1) fork pads are serviceable and can be
replaced if necessary.
Check both of the sleeves for wear or damage, espe-
cially on the interior teeth. Replace the sleeves if wear
or damage is evident.
REAR EXTENSION HOUSING
Inspect the extension housing seal and bushing. Replace both components if either show any sign of wear or dam-
age.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
Inspect the shaft threads, sprocket teeth, and bearing surfaces. Minor nicksontheteethcanbesmoothedwithan
oilstone. Use 320-400 grit emery to smooth minor scratches on the shaft bearing surfaces. Rough threads on the
shaft can be chased if necessary. Replace the shaft if the threads are damaged, bearing surfaces are scored, or if
any sprocket teeth are cracked or broken.
Examine the drive chain and shaft bearings. Replace the chain and both sprockets if the chain is stretched, dis-
torted, or if any of the links bind. Replace the bearings if rough, or noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear (2) condition carefully. The gear
is only serviced as part of the front case (1). If the
gear is damaged, it will be necessary to replace the
gear and front case as an assembly. Do not attempt to
remove the gear.
FRONT AND REAR CASES
Inspect the cases for wear and damage.
Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces. Also
make sure the front case mounting studs are in good condition.
Check the front case mounting studs and vent tube. The tube can be secured with Loctite™ 271 or 680 if loose.
Thestudthreadscanbecleanedupwithadieifnecessary.Alsocheckcondition of the fill/drain plug threads in the
rear case. The threads can be repaired with a thread chaser or tap if necessary. Or the threads can be repaired with
Helicoil
stainless steel inserts if required.

OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the pump if any part appears to beworn or damaged. Do not disas-
semble the pump as individual parts are not available. The pump is only available as a complete assembly. The
pickup screen, hose, and tube are the only serviceable parts and are available separately.
ASSEMBLY
BEARINGS AND SEALS
1. Remove the input shaft bearing (1) from the front
case (2) with suitable snap-ring pliers.
2. Transfer the retaining ring to the new bearing if
necessary and install the bearing into the front
case.
3. Using Bearing Installer 6436 (2) and Universal
Handle C-4171 (3), remove front output shaft bear-
ing.
4. Start front output shaft bearing in case. Then seat
bearing with Universal Handle C-4171 and Bearing
Remover/Installer 6953.
5. Install front output shaft bearing retaining ring.

9. Install spring (2) and cup (1) on shift rail.
10. 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.
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 (1) and oil pump
assembly onto the front case (2).