Replace the transfer case chain in a 2014 Ram 2500 with 6.7L Cummins diesel, requiring transfer case removal, disassembly, chain replacement, and reassembly with proper fluid refill.

Warnings

Tools required

Parts

• Transfer case chain × 1 — Use OEM or heavy-duty replacement
• Transfer case gasket kit × 1 — Use OEM specification
• Transfer case output shaft seal × 1 — Use OEM specification
• Transfer case input shaft seal × 1 — Use OEM specification
• Drain plug washer × 1 — Crush washer
• Transfer case filter (if equipped) × 1 — Check for internal filter
• RTV silicone sealant × 1 — Mopar or equivalent

Fluids

• Mopar Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Raise vehicle on lift or jack stands at all four corners to working height
4. Remove skid plate if equipped
5. Disconnect negative battery cable
6. Allow transfer case to cool if vehicle was recently operated
7. Clean exterior of transfer case to prevent contamination during disassembly
8. Take photos of linkage and electrical connections for reference during reassembly

Procedure

1. 1

   Drain transfer case fluid
   Place drain pan under transfer case. Remove drain plug from bottom of transfer case and allow fluid to drain completely. Inspect drained fluid for metal particles or debris indicating chain wear. Remove fill plug to aid drainage. Reinstall drain plug with new crush washer.
2. 2

   Remove front and rear driveshafts
   Mark orientation of front driveshaft to transfer case yoke and front axle yoke with paint or punch marks. Remove four U-joint strap bolts at transfer case end and at front axle end. Support driveshaft and remove. Repeat process for rear driveshaft, marking orientation at transfer case and rear axle. Support driveshafts out of way or remove completely.
   ⚠Driveshafts are heavy and can fall when detached. Support properly before removing final bolts.
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)
3. 3

   Disconnect linkage and electrical connections
   Disconnect transfer case shift linkage at transfer case. Remove shift motor electrical connector if equipped with electronic shift. Disconnect vent hose from top of transfer case. Label or photograph all connections for proper reassembly.
4. 4

   Support and remove transfer case
   Position transfer case jack or transmission jack under transfer case. Secure transfer case to jack with safety chain or strap. Remove transfer case mounting bolts (typically 6 bolts). Carefully slide transfer case rearward off transmission output shaft while supporting weight on jack. Lower transfer case and move to clean workbench.
   ⚠️Transfer case is heavy and awkward. Ensure jack is positioned securely and use assistant if available.
   Torque spec

   Mounting Bolts37 Nm (27 lb-ft)
5. 5

   Disassemble transfer case rear half
   With transfer case on workbench, remove rear case cover bolts. Carefully separate rear case half from front case half using plastic mallet to tap on case casting (not sealing surfaces). Remove rear output shaft bearing retainer and output shaft assembly. Note position and orientation of all components.
   ℹ️Use holding fixture or wooden blocks to stabilize transfer case during disassembly.
   Torque spec

   Cover Screws15 Nm (11 lb-ft)
6. 6

   Remove chain and sprockets
   Remove chain from drive sprocket and driven sprocket. Inspect chain for wear, stretched links, or damaged rollers. Remove sprocket snap rings using snap ring pliers. Remove drive sprocket and driven sprocket. Mark orientation if sprockets are directional. Inspect sprocket teeth for wear, grooves, or damage.
7. 7

   Inspect bearings and shafts
   Inspect all bearings for roughness, pitting, or noise when rotated. Check input shaft and output shafts for wear or scoring. Replace any worn components. Inspect shift fork pads and synchronizer if equipped. Check case halves for cracks or damage.
   ⚠If significant wear is found on bearings or shafts, these components must be replaced to prevent premature chain failure.
8. 8

   Clean and prepare case halves
   Thoroughly clean both case halves, removing all old gasket material and RTV sealant. Use solvent and plastic scraper to avoid damaging sealing surfaces. Clean all passages and check for debris. Dry completely with compressed air. Inspect sealing surfaces for damage or warping.
9. 9

   Install new chain and sprockets
   Install driven sprocket onto shaft in correct orientation. Install snap ring to secure. Install drive sprocket onto input shaft. Install new transfer case chain over both sprockets, ensuring proper engagement. Check chain tension and endplay per service specifications (typically 0.5-1.0 inch free play at midpoint).
   ℹ️Some transfer case chains have directional rotation markings. Verify correct installation direction.
10. 10

    Reassemble case halves
    Apply thin bead of RTV silicone sealant to front case half mating surface as specified in service manual (or install new gasket if equipped). Install rear output shaft assembly with bearing retainer. Carefully align rear case half with front case half, ensuring proper engagement of all components. Install case half bolts and tighten in criss-cross pattern to proper torque specification.
    ⚠Ensure all shift components are properly aligned before joining case halves to prevent binding.
    Torque spec

    Cover Screws15 Nm (11 lb-ft)
11. 11

    Install new seals
    Remove old input shaft seal and output shaft seals using seal pick or puller. Clean seal bores thoroughly. Install new input shaft seal with seal driver, ensuring proper depth and alignment. Install new front and rear output shaft seals. Apply light coating of transfer case fluid to seal lips.
12. 12

    Reinstall transfer case to transmission
    Apply light coating of grease to transmission output shaft splines. Position transfer case on jack and raise into position. Align transfer case input shaft with transmission output shaft. Slide transfer case forward onto transmission, ensuring proper engagement. Install mounting bolts and tighten in criss-cross pattern.
    ⚠Do not force transfer case onto transmission. If resistance is felt, check alignment and spline engagement.
    Torque spec

    Mounting Bolts37 Nm (27 lb-ft)
13. 13

    Reconnect components and driveshafts
    Reconnect transfer case shift linkage and adjust if necessary. Connect shift motor electrical connector. Install vent hose. Install front driveshaft, aligning marks made during removal. Install U-joint straps and tighten bolts evenly. Repeat for rear driveshaft, ensuring proper phasing.
    Torque spec

    Driveshaft U-Joint Straps20 Nm (15 lb-ft)
14. 14

    Refill transfer case and test
    Remove fill plug. Using gear oil pump, fill transfer case with 2.5 quarts of Mopar Transfer Case Fluid through fill hole until fluid reaches bottom of fill hole. Install fill plug. Reconnect battery. Lower vehicle. Start engine and shift through all transfer case positions (2WD, 4WD High, 4WD Low if equipped) to verify proper operation. Check for leaks around seals and case halves.
    ℹ️Some transfer cases require specific fill procedure. Verify fluid level with vehicle on level surface.
15. 15

    Final inspection and road test
    Verify all mounting bolts are properly torqued. Check that all electrical connections are secure. Reinstall skid plate if equipped. Test drive vehicle in 2WD and 4WD modes to verify proper operation. Listen for abnormal noises. Check fluid level after test drive and verify no leaks are present.

Reassembly

1. Torque all fasteners to specification in proper sequence
2. Use new gaskets and seals throughout reassembly
3. Apply RTV sealant sparingly to avoid excess squeezing into internal passages
4. Verify proper alignment of driveshaft marks to prevent vibration
5. Fill transfer case to proper level with correct Mopar fluid only

Verification

• Test drive vehicle and verify smooth shifting between 2WD and 4WD modes with no grinding or binding
• Listen for chain noise during acceleration and deceleration in 4WD mode
• Verify no fluid leaks from transfer case seals or case mating surfaces after test drive
• Check that 4WD indicator light functions properly for all transfer case positions
• Recheck fluid level after test drive and top off if necessary
• Verify no vibration is present at highway speeds indicating proper driveshaft phasing

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