Transfer Case

This procedure covers the removal and installation of the transfer case on a 1994-2007 Dodge Ram 2500 with 5.9L Cummins diesel engine and 4WD.

Warnings

Tools required

Parts

• Transfer case output seal (rear) × 1 — Use OEM specification
• Transfer case input seal × 1 — Use OEM specification
• Transfer case gasket or RTV sealant × 1 — Mopar RTV or equivalent
• Shop towels × 1 — Standard

Fluids

• Mopar ATF+4 for transfer case — 4.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable
3. Raise vehicle and support securely on jack stands at frame rails, ensuring adequate clearance for transfer case removal
4. Remove skid plate if equipped
5. Place drain pan under transfer case and remove drain plug to drain fluid completely
6. Allow sufficient time for fluid to drain while preparing other components

Procedure

1. 1

   Mark and disconnect front driveshaft
   Mark the front driveshaft flange orientation to the transfer case yoke using a paint pen or marker. Remove the fasteners (U-bolt straps or flange bolts as equipped) securing the front driveshaft to the transfer case yoke. Support the driveshaft and secure it out of the way with wire or rope to prevent damage to the U-joints or bearing caps.
   Torque spec

   Driveshaft Flange Bolts20 Nm (15 lb-ft)
2. 2

   Mark and disconnect rear driveshaft
   Mark the rear driveshaft orientation to the transfer case output yoke. Remove the driveshaft bolts at the transfer case end. If your model has strap-style retainers, remove the U-bolts. Support the driveshaft and slide it rearward to separate from the transfer case output shaft, then secure out of the way.
   Torque spec

   Driveshaft Bolts75 Nm (55 lb-ft)
3. 3

   Disconnect shift linkage and electrical connections
   Disconnect the transfer case shift linkage at the case. For manual shift models, remove the shift rod retaining clip and slide the rod off the shift lever. For electronic shift models, disconnect the shift motor electrical connector. Also disconnect the speed sensor electrical connector if equipped. Label connections if necessary for reassembly.
   ℹ️Take photos of linkage positions before removal to aid in proper reassembly and shift adjustment.
4. 4

   Disconnect vent hose and breather
   Locate the transfer case vent hose, typically running up toward the frame rail. Disconnect the vent hose from the transfer case. Note the routing for reinstallation to prevent water intrusion into the case.
5. 5

   Support transfer case with transmission jack
   Position a transmission jack or suitable support under the transfer case. Secure the transfer case to the jack using a chain or strap. Raise the jack slightly to take the weight off the mounting points, but do not attempt to remove the case yet.
   ⚠Ensure the transfer case is securely fastened to the jack before removing mounting bolts. The case will shift when bolts are removed.
6. 6

   Remove transfer case mounting bolts
   Remove the transfer case-to-transmission mounting bolts/nuts (typically five or six depending on model). These are located around the perimeter of the transfer case adapter. Keep track of bolt locations as some may be different lengths. Support the case on the jack throughout this process.
   Torque spec

   Transfer Case Bolts35 Nm (26 lb-ft)
7. 7

   Separate and lower transfer case
   Carefully slide the transfer case rearward to disengage the input shaft from the transmission output shaft. This may require slight prying with a pry bar between the transmission and transfer case. Once separated, carefully lower the transfer case on the transmission jack. Be prepared for additional fluid drainage. Guide the case around any obstructions as you lower it to the ground.
   ⚠The transfer case is heavy and awkward. Have an assistant guide the case while lowering to prevent it from binding or falling.
8. 8

   Inspect and clean mating surfaces
   With the transfer case removed, inspect the transmission output shaft, transfer case input shaft, and both mating surfaces for damage or excessive wear. Clean all mating surfaces thoroughly with a wire brush and solvent. Remove all old gasket material or RTV sealant. Inspect the transfer case input seal and replace if worn or leaking.
9. 9

   Prepare transfer case for installation
   If installing a replacement transfer case, ensure it is filled to the proper level with the manufacturer-specified fluid (Mopar ATF+4 for 1998 and later; ATF+3/Dexron for 1994-1997 models). Install a new gasket or apply a thin bead of RTV sealant to the transfer case mounting surface according to manufacturer specifications. Replace the input seal if removed. Verify the transfer case is in the correct gear range position (typically 2WD high) to align with shift linkage.
10. 10

    Raise and align transfer case
    Position the transfer case on the transmission jack and raise it into position. Carefully align the transfer case input shaft with the transmission output shaft. This may require rotating the transfer case output shaft slightly while pushing forward to engage the splines. Guide the case forward until the mounting surface contacts the transmission adapter.
    ℹ️Do not force the transfer case. If it does not slide on easily, lower it slightly and verify spline alignment.
11. 11

    Install transfer case mounting bolts
    Install all six transfer case mounting bolts and tighten them in a cross-pattern to ensure even seating. Torque all bolts to specification. Once secure, you may remove the transmission jack support.
    Torque spec

    Transfer Case Bolts35 Nm (26 lb-ft)
12. 12

    Reconnect vent hose and electrical connections
    Reconnect the transfer case vent hose, ensuring it is routed properly away from heat sources and moving components. Reconnect the shift motor electrical connector (electronic shift) or install the shift linkage rod (manual shift). Reconnect the speed sensor electrical connector if equipped.
13. 13

    Install rear driveshaft
    Position the rear driveshaft and align the marks made during removal. Slide the driveshaft forward onto the transfer case output shaft, aligning the flange or yoke. Install the driveshaft bolts or U-bolt straps and torque to specification.
    Torque spec

    Driveshaft Bolts75 Nm (55 lb-ft)
14. 14

    Install front driveshaft
    Raise the front driveshaft into position and align the marks made during removal. Install the four flange bolts and torque to specification. Ensure the driveshaft has proper clearance throughout its range of motion.
    Torque spec

    Driveshaft Flange Bolts20 Nm (15 lb-ft)
15. 15

    Fill transfer case and final checks
    Install the transfer case drain plug if equipped. Using the fill plug on the side of the transfer case, fill with the manufacturer-specified fluid (approximately 2 to 3.5 quarts depending on model) until fluid reaches the bottom of the fill hole. Install the fill plug. Reinstall skid plate if equipped. Lower the vehicle and reconnect the negative battery cable(s) (this diesel uses a dual-battery system).

Reassembly

1. Verify all electrical connections are secure and properly routed
2. Check that all driveshaft bolts are torqued to specification and properly aligned
3. Ensure shift linkage operates smoothly through all transfer case positions
4. Double-check that the vent hose is properly routed and connected to prevent water intrusion

Verification

• Start the engine and shift the transfer case through all positions (2H, 4H, 4L, N) to verify proper operation
• Check for fluid leaks around the transfer case mounting surface, input seal, and output seal
• Test drive the vehicle in both 2WD and 4WD modes to confirm proper engagement and operation
• After test drive, recheck transfer case fluid level when vehicle is on level ground and add if necessary
• Verify no unusual noises or vibrations are present during operation in any gear range

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