300, 300C & Magnum 2006-2008, Charger 2006-2008

Transfer Case Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise support vehicle.
  4.  
  5. Disconnect the front and rear driveshafts from the transfer case.
  6.  
  7. Support transmission with jackstand.
  8.  
  9. Remove the bolts holding the transmission crossmember to the frame.

    Click image to see an enlarged view

    Fig. Remove the bolts (2) holding the transmission crossmember (1) to the frame

  10.  
  11. Remove the bolts holding the transmission crossmember to the transmission mount.

    Click image to see an enlarged view

    Fig. Remove the bolts (2) holding the transmission mount (1) to the transfer case (3)-5.7L engine

  12.  
  13. Remove the bolts holding the transmission mount to the transfer case, 5.7L engine, and remove the transmission mount.

    Click image to see an enlarged view

    Fig. Remove the bolts (3) holding the transmission mount assembly (2) to the transfer case (1)-3.5L engine

  14.  
  15. Remove the bolts holding the transmission mount assembly to the transfer case, 3.5L engine, and remove the transmission mount assembly.
  16.  
  17. Remove the transfer case damper.
  18.  
  19. Remove the transfer case drain plug and drain transfer case lubricant.
  20.  
  21. Support transfer case with transmission jack.
  22.  
  23. Secure transfer case to jack with chains.
  24.  
  25. Lower the transmission and transfer case slightly, to improve access to the upper transfer case to transmission fasteners.
  26.  
  27. Remove nuts and bolts attaching transfer case to transmission.
  28.  
  29. Pull transfer case and jack rearward to disengage transfer case.
  30.  
  31. Remove transfer case from under vehicle.
  32.  

To install:

  1. Support transfer case on a transmission jack.
  2.  
  3. Secure transfer case to jack with chains.
  4.  
  5. Position the transfer case under the vehicle and align the input shaft with the transmission output shaft.
  6.  
  7. Move the transfer case and jack forward to engage transfer case to the transmission.
  8.  
  9. Install the nuts and bolts to attach transfer case to transmission. Tighten the 120mm bolts to 18 ft. lbs. (25 Nm), the 30mm bolts to 20 ft. lbs. (27 Nm), and the nuts to15 ft. lbs. (20 Nm)
  10.  
  11. Raise the transmission and transfer case into their normal position.
  12.  
  13. Fill the transfer case with the appropriate fluid.
  14.  
  15. Install the transfer case damper.
  16.  
  17. Install the transmission mount assembly to the transfer case and install the bolts to hold the transmission mount assembly to the transfer case, 3.5L engine. Tighten the bolts to 41 ft. lbs. (55 Nm).
  18.  
  19. Install the transmission mount to the transfer case and install the bolts to hold the transmission mount to the transfer case, 5.7L engine. Tighten the bolts to 50 ft. lbs. (68 Nm).
  20.  
  21. Install the bolts to hold the transmission crossmember to the transmission mount. Tighten the bolts to 48 ft. lbs. (65 Nm).
  22.  
  23. Install the bolts to hold the transmission crossmember to the frame. Tighten the bolts to 50 ft. lbs. (68 Nm).
  24.  
  25. Install the front and rear driveshafts to the transfer case.
  26.  

 
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