2006 DODGE RAM SRT-10 sensor

17. Install the transfer case position sensor or switch
(2). Tighten the sensor or switch to 20-34 Nꞏm
(16-25 ft. lbs.) torque.
18. Install range lever (1) on sector shaft.
19. Install washer and nut on sector shaft to secure
shift lever. Apply 1-2 drops Mopar
Lock N’ Seal,
or equivalent, to nut threads before installation.
Then tighten nut to 27-34 Nꞏm (20-25 ft. lbs.)
torque.
20. Install new o-ring on detent plug (2).

SEAL BOOT
1. 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.
2. Install a new seal boot clamp onto the seal boot.
3. Install the seal boot and clamp onto the slinger hub and tighten the clampwith Crimp Tool C-4975-A.
REAR EXTENSION
1. Install new seal in rear extension housing seal with
Seal Installer D-163 and universal Handle C-4171..
2. 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.
3. Align and install rear extension housing (1) on
retainer.
4. Apply Mopar
Silicone Sealer to threads of rear
extension housing bolts. Then install and tighten
bolts to 16-24 Nꞏm (12-18 ft. lbs.) torque.
INSTALLATION
1. Align and seat transfer case on transmission. Be sure transfer case input gear splines are aligned with trans-
mission output shaft. Align splines by rotating transfer case rear outputshaft yoke if necessary. Do not install any
transfer case attaching nuts until the transfer case is completely seatedagainst the transmission.
2. Install and tighten transfer case attaching nuts. Tighten nuts to 30-41Nꞏm (20-30 ft.lbs.).
3. Remove jack stand from under transmission.
4. Align and connect propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPEL-
LER SHAFT - INSTALLATION)
5. Connect vent hose and transfer case position sensor connector.
6. Connect shift rod to transfer case lever or floor shift arm. Use channel lock style pliers to press rod back into
lever grommet.
7. Adjust shift linkage, if necessary.
8. Fill transfer case with recommended transmission fluid and install fillplug.
9. Install skid plate, if equipped. (Refer to 13 - FRAMES & BUMPERS/FRAME/TRANSFER CASE SKID PLATE -
INSTALLATION)
10. Lower vehicle
SPECIFICATIONS
TRANSFER CASE - NV241 GENII
TORQUE SPECIFICATIONS

DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Extension Housing 16-24 12-18 -
Bolt, Case Half 20-27 15-24 -
Screw, Oil Pump 12-16 8-12 -
Nut, Range Lever 27-34 20-25 -
Sector Support 27-42 20-30 -
Nuts, Mounting 30-41 20-30 -
Position Sensor 20-34 16-25 -

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TRANSFER CASE - NV271 - SERVICE
INFORMATION
DESCRIPTION ............................. 1606
OPERATION ............................... 1606
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV271 ............................ 1607
REMOVAL ................................. 1608
DISASSEMBLY ............................. 1608
CLEANING ................................. 1623
INSPECTION ............................... 1623
ASSEMBLY . ............................... 1626
INSTALLATION ............................. 1644
SPECIFICATIONS
TRANSFER CASE - NV271 ................ 1645
SPECIAL TOOLS
TRANSFER CASE NV271/NV273 ........... 1646
BOOT-EXTENSION HOUSING SEAL AND DUST
REMOVAL ................................. 1648INSTALLATION ............................. 1648
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL ................................... 1649
SEAL-FRONT OUTPUT SHAFT
REMOVAL ................................. 1650
INSTALLATION ............................. 1650
SENSOR-POSITION
DESCRIPTION ............................. 1651
OPERATION ............................... 1651
REMOVAL ................................. 1651
INSTALLATION ............................. 1652
LEVER-SHIFT
REMOVAL ................................. 1653
INSTALLATION ............................. 1654
ADJUSTMENTS
ADJUSTMENT - SHIFT LEVER............. 1655

Condition Possible Cause Correction
Lubricant leaking from output shaft
seal or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Vent closed or restricted. 2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or
installed incorrectly.3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.1) Operate vehicle in the 2H
position on hard, dry surfaces.
REMOVAL
1. Raise and support vehicle.
2. Remove skid plate, if equipped. (Refer to 13 - FRAMES & BUMPERS/FRAME/TRANSFER CASE SKID PLATE
- REMOVAL)
3. Position drain oil container under transfer case.
4. Remove transfer case drain plug and drain lubricant into container.
5. Disconnect vent hose and transfer case position sensor connector.
6. Disconnect shift rod from grommet in transfer case shift lever, or from floor shift arm whichever provides easy
access. Use channel lock style pliers to press rod out of lever grommet.
7. Support transmission with jack stand.
8. Mark front and rear propeller shafts for assembly reference.
9. Remove front and rear propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - REMOVAL)
10. Support transfer case with suitable jack. Secure transfer case to jackwith safety chains.
11. Remove nuts attaching transfer case to transmission.
12. Move transfer case assembly rearward until free of transmission outputshaft.
13. Lower jack and move transfer case from under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubricant remaining in
case.

SHIFT FORKS AND MAINSHAFT
1. Shift transfer case into NEUTRAL.
2. Remove nut that retains the shift lever to sector
shaft. Then remove shift lever (3) and spacer from
the shaft.
3. Remove the sector support (2) with Socket 9033.
4. Remove the transfer case position sensor or switch
(2) from the front case half (1).
5. Loosen detent plug (2).

13. Install the transfer case position sensor or switch
(2). Tighten the sensor or switch to 20-34 Nꞏm
(15-25 ft. lbs.) torque.
14. Install manual shift lever (3)and spacer onto sec-
tor shaft (1).
15. Install washer and nut on sector shaft to secure
shift lever. Apply 1-2 drops Mopar
Lock N’ Seal,
or equivalent, to nut threads before installation.
Then tighten nut to 27-34 Nꞏm (20-25 ft. lbs.)
torque.
16. Install new o-ring (1) on detent plug (2).

6. Install the extension housing boot and seal assem-
bly with Seal Installer 9037 (3) and Universal Han-
dle C-4171 (2).
7. Install the front companion flange onto the front
output shaft.
8. Install two bolts 180° apart into the front output
shaft companion flange.
9. Place holder (1) over the bolts (2) and against the
companion flange.
10. Install a new front companion flange nut. Tighten
the companion flange nut to 176-271 Nꞏm
(130-200 ft.lbs.).
INSTALLATION
1. Align and seat transfer case on transmission. Be sure transfer case input gear splines are aligned with trans-
mission output shaft. Align splines by rotating transfer case rear outputshaft yoke if necessary. Do not install any
transfer case attaching nuts until the transfer case is completely seatedagainst the transmission.
2. Install and tighten transfer case attaching nuts. Tighten nuts to 30-41Nꞏm (20-30 ft.lbs.).
3. Remove jack stand from under transmission.
4. Align and connect propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPEL-
LER SHAFT - INSTALLATION)
5. Connect vent hose and transfer case position sensor connector.
6. Connect shift rod to transfer case lever or floor shift arm. Use channel lock style pliers to press rod back into
lever grommet.
7. Adjust shift linkage, if necessary.
8. Fill transfer case with recommended transmission fluid and install fillplug.