This procedure covers draining and refilling the BorgWarner BV206 transfer case fluid on a 2014 Ram 2500 4WD with the 6.7L Cummins diesel engine.

Warnings

Tools required

Parts

• Oil drain plug crush washer × 1 — 6508366AA or equivalent copper washer

Fluids

• Mopar Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on a level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. If possible, drive vehicle for 5-10 minutes to warm transfer case fluid for easier drainage
4. Raise front of vehicle using floor jack at designated front lift points
5. Secure vehicle on jack stands rated for vehicle weight
6. Allow transfer case to cool for 10 minutes if recently driven to avoid burns from hot fluid

Procedure

1. 1

   Access transfer case drain area
   Position yourself under the vehicle behind the transmission. Locate the transfer case which is mounted directly behind the transmission. The drain plug is on the bottom rear of the transfer case housing. Clean the area around the drain plug with a wire brush to prevent contamination during service.
2. 2

   Remove fill plug first
   Locate the fill plug on the passenger side of the transfer case housing, approximately mid-height. Using a 10mm socket, carefully loosen and remove the fill plug. Verify the plug comes out freely before draining. If the fill plug is seized or stripped, do not proceed with draining until it can be removed.
   ⚠Always remove the fill plug before the drain plug to ensure you can refill the transfer case after draining.
3. 3

   Drain transfer case fluid
   Position drain pan directly beneath the transfer case drain plug. Using a 13mm socket, slowly loosen the drain plug. Once loose, carefully remove by hand and allow fluid to drain completely. Inspect the drained fluid for metal particles or debris which may indicate internal wear. Allow at least 10-15 minutes for complete drainage.
   ⚠Fluid may still be hot enough to cause burns. Wear appropriate gloves and eye protection.
4. 4

   Inspect and prepare drain plug
   Remove the old crush washer from the drain plug and discard. Clean the drain plug threads with a shop rag. Inspect the plug threads for damage. Install a new crush washer on the drain plug. Clean the drain hole threads on the transfer case with a clean rag.
5. 5

   Reinstall drain plug
   Thread the drain plug with new crush washer into the transfer case by hand to ensure proper thread engagement. Using a 13mm socket and torque wrench, tighten the drain plug to specification. Do not overtighten as this can damage the aluminum housing.
   Torque spec

   Oil Drain Plug35 Nm (26 lb-ft)
6. 6

   Refill transfer case
   Using a fluid transfer pump or squeeze bottle with extension tube, insert the fill tube into the fill hole. Slowly add Mopar Transfer Case Fluid. Fill until fluid begins to drip from the fill hole, indicating proper level. The transfer case capacity is approximately 2.5 quarts. Allow fluid to settle for 1-2 minutes and top off if level drops.
   ℹ️Only use Mopar Transfer Case Fluid. Use of incorrect fluid can cause transfer case damage and void warranty.
7. 7

   Reinstall fill plug
   Clean the fill plug threads and wipe any spilled fluid from the transfer case exterior. Thread the fill plug by hand, then tighten with a 10mm socket. These plugs do not require high torque; snug them firmly but do not overtighten the aluminum threads.
8. 8

   Clean work area and lower vehicle
   Wipe down the transfer case exterior to remove any spilled fluid. Check for drips from both drain and fill plugs. Remove jack stands and carefully lower vehicle to ground. Dispose of used transfer case fluid properly at a recycling center or approved waste facility.

Reassembly

1. Ensure both drain and fill plugs are properly torqued and not leaking
2. Verify proper fluid level by confirming fluid was at fill hole during refill procedure
3. Dispose of old transfer case fluid according to local environmental regulations

Verification

• Start engine and shift through all transfer case positions (2H, 4H, 4L if equipped) to circulate new fluid
• Check for leaks around drain and fill plugs with vehicle running
• Take a short test drive (5-10 minutes) and recheck for leaks after vehicle has cooled
• Verify smooth transfer case operation with no unusual noises or binding during 4WD engagement
• Monitor for leaks during the first 100 miles of operation

More procedures for this vehicle