drivetrain

Transfer Case Encoder Motor

for 2014 Ram 2500 6.7L I6 Cummins Diesel · 4WD

Difficulty

Moderate

Time

4.6 h

Tools

Steps

Replace the transfer case encoder motor which controls the shifting between 2WD and 4WD modes on the BW 44-47 transfer case.

Warnings

⚠Perform this work with the transfer case cold. Hot transfer case fluid can cause burns.

⚠Vehicle must be in PARK with parking brake engaged. Improper support can result in vehicle rolling.

ℹ️Some transfer case fluid may drain when removing the encoder motor. Have a drain pan ready.

⚠️Ensure vehicle is properly supported on jack stands rated for the vehicle weight. Never work under a vehicle supported only by a jack.

Tools required

Socket set (metric)Essential

Torque wrenchEssential

Jack and jack standsEssential

Wheel chocksEssential

Drain pan (if fluid replacement needed)

Wire brush

Electrical contact cleaner

Ratcheting wrench set

Pry bar (small)

Shop towelsEssential

Parts

Transfer case encoder motor × 1 — Mopar 68272406AA or equivalent
Encoder motor O-ring/gasket × 1 — Usually included with motor
Transfer case fluid (if topping off) × 1 — Mopar Transfer Case Fluid

Fluids

Mopar Transfer Case Fluid — 0.5 qt

Preparation

Park vehicle on level surface and engage parking brake
Place wheel chocks behind rear wheels
Disconnect negative battery cable to prevent inadvertent 4WD system activation
Raise vehicle and support securely on jack stands
Allow transfer case to cool completely if recently driven

Procedure

1
Access transfer case encoder motor
Locate the encoder motor on the rear of the transfer case, driver's side. It is a cylindrical component with an electrical connector. Remove any skid plates or heat shields that may obstruct access. Clean the area around the encoder motor with a wire brush to remove dirt and debris.
2
Disconnect electrical connector
Press the release tab on the encoder motor electrical connector and carefully pull the connector straight off the motor. Inspect the connector terminals for corrosion or damage. If corroded, clean with electrical contact cleaner and allow to dry completely.
3
Position drain pan
Place a drain pan beneath the encoder motor location. While the encoder motor is on the side of the transfer case, some fluid (typically 1/4 to 1/2 quart) may drain out when the motor is removed, depending on fluid level and vehicle position.
4
Remove encoder motor mounting bolts
Remove the three mounting bolts securing the encoder motor to the transfer case using a socket or ratcheting wrench. Keep bolts organized for reinstallation. Note the bolt locations as they may be different lengths.
Torque spec
Mounting Bolts37 Nm (27 lb-ft)
5
Remove encoder motor
Carefully pull the encoder motor straight out from the transfer case. The motor shaft engages with the mode fork inside the transfer case. If stuck, gently rotate the motor while pulling to disengage. Catch any fluid that drains. Do not pry against the transfer case housing.
6
Inspect and clean mounting surface
Inspect the encoder motor bore in the transfer case for debris or metal shavings. Remove the old O-ring or gasket from the transfer case mounting surface. Clean the mounting surface thoroughly with a shop towel and ensure it is free of old gasket material, dirt, and fluid residue. Inspect the bore for damage.
7
Prepare new encoder motor
Remove the new encoder motor from packaging and verify it matches the old unit. Install the new O-ring or gasket onto the new encoder motor. Lightly lubricate the O-ring with clean transfer case fluid to aid installation and prevent tearing. Ensure the O-ring is seated properly in the motor groove.
8
Install new encoder motor
Align the encoder motor shaft with the mode fork inside the transfer case. You may need to rotate the motor slightly to engage the fork properly. Push the motor in firmly until it seats flush against the transfer case housing. The motor should slide in smoothly without forcing.
9
Install mounting bolts
Install the three mounting bolts hand-tight, ensuring the motor remains properly seated. Torque the bolts in a star pattern to the specified value to ensure even seating and prevent O-ring distortion.
⚠Do not over-torque mounting bolts. Excessive torque can damage the transfer case housing or encoder motor.
Torque spec
Mounting Bolts37 Nm (27 lb-ft)
10
Reconnect electrical connector
Reconnect the electrical connector to the encoder motor, ensuring it clicks into place and is fully seated. Verify the connector lock tab is engaged. Route the wiring away from hot or moving components.
11
Check and top off transfer case fluid
Locate the transfer case fill plug on the rear of the case. Remove the fill plug and check fluid level. Fluid should be at the bottom of the fill hole threads. If low due to fluid loss during encoder motor removal, add Mopar Transfer Case Fluid until it begins to seep from the fill hole. Reinstall fill plug.
12
Reinstall shields and lower vehicle
Reinstall any skid plates or heat shields removed during access. Ensure all fasteners are tight. Lower vehicle from jack stands and remove wheel chocks. Reconnect negative battery cable.

Reassembly

Verify all mounting bolts are torqued to specification
Ensure electrical connector is fully seated and locked
Confirm transfer case fluid level is correct
Double-check that all removed components (shields, skid plates) are reinstalled

Verification

Start engine and verify no warning lights on instrument cluster related to 4WD system
Cycle through all transfer case positions (2WD, 4WD High, 4WD Low, Neutral) using the transfer case selector and verify proper engagement in each mode
Listen for unusual noises from transfer case during mode changes
Check for fluid leaks around encoder motor after test drive
Verify 4WD indicator lights illuminate correctly on dash when 4WD modes are selected
Perform a short test drive and confirm proper 4WD operation in both high and low range