This procedure replaces the transfer case motor/actuator on a 2014 Ram 2500 4WD with the 6.7L Cummins diesel engine, which controls engagement of the transfer case for 4WD operation.

Warnings

Tools required

Parts

• Transfer case shift motor/actuator × 1 — Use OEM specification
• Transfer case actuator O-ring or gasket × 1 — Usually included with actuator
• RTV silicone sealant (if gasket not included) × 1 — Mopar specified RTV

Fluids

• Mopar Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Allow transfer case to cool completely if vehicle has been operated
3. Disconnect negative battery cable to prevent accidental 4WD engagement during repair
4. Raise vehicle and support securely on jack stands at manufacturer-specified lift points
5. Place drain pan under transfer case actuator area to catch fluid spillage

Procedure

1. 1

   Locate and inspect transfer case actuator
   From underneath the vehicle, locate the transfer case shift motor/actuator on the driver's side of the transfer case. It is an electric motor assembly with an electrical connector and typically 2-3 mounting bolts. Inspect the area for debris or damage and clean around the mounting area with a wire brush if needed.
2. 2

   Disconnect electrical connector
   Locate the electrical connector on the transfer case actuator. Press the release tab and carefully pull the connector straight off the actuator. If the connector is corroded or difficult to remove, apply slight side-to-side rocking motion while pulling. Inspect connector pins for corrosion or damage.
3. 3

   Position drain pan
   Position drain pan directly beneath the actuator motor. When the actuator is removed, transfer case fluid will drain from the opening. Ensure drain pan has adequate capacity and is positioned to catch all fluid.
4. 4

   Remove actuator mounting bolts
   Remove the mounting bolts securing the transfer case actuator to the transfer case housing. There are typically 2-3 bolts. Keep bolts organized for reinstallation. Note the position and depth of each bolt as they may be different lengths.
   ⚠Have drain pan ready as fluid will begin draining immediately when actuator is loosened.
   Torque spec

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

   Remove old actuator
   Carefully pull the actuator straight out from the transfer case housing. Expect transfer case fluid to drain from the opening. If actuator is stuck, use gentle side-to-side rocking motion while pulling. Do not pry against aluminum transfer case housing. Allow fluid to drain completely into drain pan.
6. 6

   Inspect and clean mounting surface
   Once fluid drainage slows, inspect the transfer case opening and mounting surface. Remove old gasket material or O-ring from the transfer case housing using a plastic scraper (never metal on aluminum). Clean the mounting surface thoroughly with shop rags. Inspect internal splines or shift fork mechanism visible through opening for damage or excessive wear.
7. 7

   Prepare new actuator
   Remove new actuator from packaging and verify it matches the old unit. Install new O-ring or gasket onto the new actuator. If using RTV silicone sealant instead of a gasket, apply a thin, even bead to the actuator mounting flange. Lightly lubricate the O-ring with clean transfer case fluid to ease installation.
8. 8

   Install new actuator
   Align the new actuator with the mounting holes and internal shift mechanism. The actuator shaft must engage with the internal shift components. Push the actuator straight into the transfer case housing, ensuring proper alignment. The actuator should seat flush against the mounting surface. If resistance is felt, rotate actuator slightly to align internal splines, but do not force.
9. 9

   Install and torque mounting bolts
   Install the mounting bolts finger-tight, ensuring the actuator remains properly seated and aligned. Tighten bolts evenly in a cross pattern to avoid cocking the actuator. Using a torque wrench, torque mounting bolts to specification.
   Torque spec

   Mounting Bolts37 Nm (27 lb-ft)
10. 10

    Reconnect electrical connector
    Reconnect the electrical connector to the new actuator, ensuring it clicks fully into place. Verify the connector lock tab is properly engaged. Gently tug on the connector to confirm it is secure.
11. 11

    Refill transfer case fluid
    Locate the transfer case fill plug (typically on the passenger side of the transfer case). Remove the fill plug and use a fluid pump or fill adapter to add Mopar Transfer Case Fluid until it reaches the bottom of the fill hole and begins to run out. Vehicle must be level for accurate fill. Install and tighten fill plug once proper level is achieved.
12. 12

    Lower vehicle and reconnect battery
    Lower vehicle from jack stands to the ground. Reconnect the negative battery cable. Ensure all tools and drain pan are removed from under the vehicle before lowering.

Reassembly

1. Ensure all mounting bolts are torqued to specification
2. Verify electrical connector is fully seated and locked
3. Confirm transfer case is filled to proper level with correct Mopar fluid
4. Check for any fluid leaks around the new actuator before test driving

Verification

• Start engine and allow to idle
• With engine running and transmission in neutral or park, shift through all 4WD modes (2H, 4H, 4L) using the dash controls and verify the transfer case engages each mode without error messages
• Check for proper indicator light operation on the instrument cluster for each 4WD mode
• Test drive vehicle in both 2WD and 4WD modes to confirm proper engagement and disengagement
• Re-check transfer case fluid level after test drive and top off if necessary
• Inspect actuator area for any fluid leaks after test drive
• If available, use a scan tool to verify no transfer case related DTCs are present

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