2006 DODGE RAM SRT-10 clutch

4. Install the mode hub 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.).

DIAGNOSIS AND TESTING - TRANSFER CASE - NV243
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer case difficult to shift or will
not shift into desired range.1) Transfer case electronically
controlled shift system malfunction.1) Verify proper operation per the
appropriate diagnostic manual.
2) If vehicle was operated for an
extended period in 4HI mode on dry
surface, driveline torque load may
cause difficulty.2) Drive the vehicle in a straight line
and momentarily release the
accelerator. The transfer case can
then be shifted to the desired mode.
3) Insufficient or incorrect lubricant. 3) Drain and refill transfer casewith
the correct quantity of Mopar
AT F
+4, Automatic Transmission Fluid.
4) Internal transfer case
components binding, worn, or
damaged.4) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.1) Insufficient or incorrect lubricant. 1) Drain and refill transfer casewith
the correct quantity of Mopar
AT F
+4, type 9602, Automatic
Transmission Fluid.
2) Internal transfer case
components binding, worn, or
damaged.2) Repair or replace components as
necessary.
Transfer case noisy while in, or
jumps out of, 4LO mode.1) Transfer case not completely
engaged in 4LO position.1) While rolling 2-3 MPH and the
transmission in NEUTRAL, or clutch
depressed on vehicles equipped
with a manual transmission, shift
transfer case to the 2WD or 4HI
position, and then back into the 4LO
position.
2) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.2) Repair or replace components as
necessary.
3) Low range gear worn or
damaged.3) Repair or replace components as
necessary.
Lubricant leaking from transfer case
seals or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.3) Replace suspect seal.
Abnormal tire wear. 1) Extended operation in 4HI mode
on dry surfaces,1) Operate vehicle in 2WD mode on
dry surfaces.

4. Remove the clutch gear (2) from the output shaft
(1).
5. Remove the sprocket hub (2) from the output shaft
(1).
6. Remove the mode hub retaining ring (2) from the
output shaft (1).

4. Install the sprocket hub (2) onto the output shaft
(1).
5. Install the clutch gear (2) onto the output shaft (1).
6. Install the drive sprocket (2) onto the output shaft
(1).

DIAGNOSIS AND TESTING
TRANSFER CASE - NV244
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
Transfer case difficult to shift or will
not shift into desired range.1) Transfer case electronically
controlled shift system malfunction.1) Verify proper operation per the
appropriate diagnostic manual.
2) Insufficient or incorrect lubricant. 2) Drain and refill transfer casewith
the correct quantity of Mopar
AT F
+4, Automatic Transmission Fluid.
3) Internal transfer case
components binding, worn, or
damaged.3) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.1) Insufficient or incorrect lubricant. 1) Drain and refill transfer casewith
the correct quantity of Mopar
AT F
+4, Automatic Transmission Fluid.
2) Internal transfer case
components binding, worn, or
damaged.2) Repair or replace components as
necessary.
Transfer case noisy while in, or
jumps out of, 4LO.1) Transfer case not completely
engaged in 4LO position.1) While rolling 2-3 MPH and the
transmission in NEUTRAL, or the
clutch depressed on vehicles
equipped with a manual
transmission, shift the transfer case
to the AWD or 4LOCK position, and
then back into the 4LO position.
2) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.2) Repair or replace components as
necessary.
3) Low range gear worn or
damaged.3) Repair or replace components as
necessary.
Lubricant leaking from transfer case
seals or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.3) Replace suspect seal.
Transfer case will not shift through
4LOCK (Part-time) range.1) Incomplete shift due to drivetrain
torque load.1)Driveinastraightlineand
momentarily release the accelerator
pedal to complete the shift.
2) Incorrect tire pressure. 2) Correct tire pressure as
necessary.
3) Excessive tire wear. 3) Correct tire condition as
necessary.
4) Excessive vehicle loading. 4) Correct as necessary.

MAINSHAFT
1. Remove intermediate clutch shaft (2) snap-ring (1).
2. Remove the intermediate clutch shaft thrust ring
(1).
3. Remove the intermediate clutch shaft (1).

5. Install the differential snap-ring (1).
6. Install the intermediate clutch shaft (1).
7. Install the clutch shaft thrust ring (1).

8. Install clutch shaft (2) snap-ring (1).
9. 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.
10. Install the shift sector o-ring.
11. 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.
12. Align and insert range fork pin in shift sector slot.