This procedure covers the removal and replacement of the transfer case on a 2014 Ram 2500 with the 6.7L Cummins diesel engine and 4WD.

Warnings

Tools required

Parts

• Transfer case (if replacing) × 1 — Use OEM specification
• Transfer case gasket/seal kit × 1 — Use OEM specification
• Transfer case mounting hardware (if corroded) × 1 — Use OEM specification

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. Disconnect negative battery cable
4. Raise vehicle using floor jack and support securely on jack stands at frame rails
5. Remove skid plate if equipped
6. Allow transfer case to cool completely if vehicle was recently driven

Procedure

1. 1

   Drain transfer case fluid
   Position drain pan beneath transfer case drain plug. Remove drain plug using appropriate socket and allow fluid to drain completely. Inspect drained fluid for metal shavings or debris. Once drained, reinstall drain plug finger-tight (will be torqued during reassembly).
2. 2

   Mark and disconnect front driveshaft
   Using paint or marker, make alignment marks on front driveshaft flange and transfer case output flange. Remove the four flange bolts connecting front driveshaft to transfer case. Support driveshaft and lower away from transfer case. Secure driveshaft to frame with mechanics wire to prevent damage.
   Torque spec

   Driveshaft Flange Bolts20 Nm (15 lb-ft)
3. 3

   Mark and disconnect rear driveshaft
   Make alignment marks on rear driveshaft flange and transfer case rear output flange. Remove the four flange bolts connecting rear driveshaft to transfer case. Support driveshaft and lower away from transfer case. Secure driveshaft to prevent it from hanging freely.
   Torque spec

   Driveshaft Flange Bolts20 Nm (15 lb-ft)
4. 4

   Disconnect electrical connectors and linkages
   Locate and disconnect the transfer case shift motor electrical connector. Disconnect the transfer case speed sensor connector if equipped. Remove any vent hose from transfer case by gently pulling off connection. Note routing of vent hose for reinstallation.
5. 5

   Support transfer case with transmission jack
   Position transmission jack with transfer case adapter beneath transfer case. Raise jack until it contacts transfer case and supports weight. Secure transfer case to jack using safety chains or straps to prevent it from shifting during removal.
   ⚠Ensure transmission jack is properly positioned and secure before proceeding. Transfer case will become unstable once mounting bolts are removed.
6. 6

   Remove transfer case mounting bolts
   Locate all transfer case-to-transmission mounting bolts (typically 5-6 bolts). Remove mounting bolts using appropriate socket and extension. Keep bolts organized and note their positions as lengths may vary. Support transfer case firmly with jack as you remove the last bolts.
   ⚠Transfer case weight will shift as bolts are removed. Maintain control of transmission jack at all times.
   Torque spec

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

   Separate and lower transfer case
   With all mounting bolts removed, carefully slide transfer case rearward to disengage input shaft from transmission output shaft. Use gentle side-to-side motion if needed to break seal. Once separated, slowly lower transfer case using transmission jack. Guide clear of vehicle frame and crossmembers.
8. 8

   Inspect and clean mating surfaces
   With transfer case removed, inspect transmission output shaft seal for leaks or damage. Clean all mating surfaces on transmission and transfer case using wire brush and shop towels. Remove old gasket material completely. Inspect transfer case input shaft and bearing for wear or damage.
9. 9

   Install new gasket and position transfer case
   Install new gasket or seal on transfer case mating surface per manufacturer instructions. Raise transfer case using transmission jack to align with transmission. Carefully align input shaft with transmission output shaft while guiding transfer case into position. Ensure gasket remains properly seated.
10. 10

    Install and torque mounting bolts
    Start all transfer case mounting bolts by hand to ensure proper thread engagement. Once all bolts are started, tighten in a star pattern to ensure even seating. Torque all mounting bolts to specification using torque wrench.
    Torque spec

    Transfer Case Bolts35 Nm (26 lb-ft)
11. 11

    Reconnect driveshafts
    Align marks made during disassembly and connect front driveshaft to transfer case output flange. Install and torque flange bolts to specification. Repeat process for rear driveshaft, ensuring alignment marks match. Verify both driveshafts are properly seated and secure.
    Torque spec

    Driveshaft Flange Bolts20 Nm (15 lb-ft)
12. 12

    Reconnect electrical and vent connections
    Reconnect transfer case shift motor electrical connector ensuring positive engagement. Reconnect speed sensor connector if equipped. Route and install vent hose to transfer case following original routing path. Ensure vent hose is not kinked or restricted.
13. 13

    Fill transfer case with fluid
    Locate transfer case fill plug on side of case. Remove fill plug and use fluid pump or funnel with hose to add 2.5 quarts of Mopar Transfer Case Fluid. Fill until fluid reaches bottom of fill hole. Install and tighten fill plug. Torque drain plug if not already completed.

Reassembly

1. Reinstall skid plate if equipped and torque fasteners to specification
2. Remove jack stands and carefully lower vehicle to ground
3. Reconnect negative battery cable
4. Check for proper transfer case operation through all shift modes before driving

Verification

• Start engine and cycle transfer case through all shift positions (2H, 4H, 4L) to verify proper operation
• Check for fluid leaks around transfer case mounting surfaces and drain/fill plugs
• Test drive vehicle in both 2WD and 4WD modes to verify proper engagement and operation
• Listen for abnormal noises from transfer case during operation
• Recheck fluid level after test drive and top off if necessary

More procedures for this vehicle