2006 DODGE RAM SRT-10 oil

INSTALLATION
1. Install the new front output shaft seal with Seal Installer MB991168A.
2. Install the front output shaft seal slinger with Oil Slinger Installer 8840. Install the slinger onto the shaft until the
tool contacts the rear of the output shaft.
3. Install a new seal boot clamp onto the seal boot.
4. Install the seal boot and clamp onto the slinger hub and tighten the clampwith Crimp Tool C-4975-A.
5. Install front propeller shaft (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPELLER
SHAFT - INSTALLATION).

OIL PUMP AND REAR CASE
1. Disengage the oil pump pick-up tube (2) from the
oil pump (1).
NOTE: The oil pump pick-up tube seals to the oil
pump with an o-ring. Verify that the o-ring was
removed with the tube and is in good condition.
Replace the o-ring if necessary.
2. Remove the oil pump (3).

FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Remove the oil pick-up tube (3) and screen from
the front case half (1).
2. Remove the front output shaft (1) drive sprocket (2)
retaining ring (3).

7. Remove input gear (1).
8. Remove bottom tabbed thrust washer (2) from low
range planetary (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.Check the pinion gear thrust washers
on the pinon pins for 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.
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

SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks (1) and mode fork
shift rail (2). Minor nicks on the shift rail can be
smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear pads (3, 4). The mode (2)
and range fork (1) 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 snap-ring from the
front case half with suitable snap-ring pliers.
2. Remove the input shaft bearing from the front case
half with Bearing Remover/Installer 6953 (3) and
Universal Handle C-4171 (2).

12. Install new bearing with Universal Handle C-4171
(2) and Bearing Installer 8128 (3).
13. The bearing bore is chamfered at the top. Install
the bearing so it is flush (1) with the lower edge of
this chamfer (2).
14. Remove seal from oil pump with suitable pry tool.
15. Install new seal in oil pump with Seal Installer
7888 (2).