Transfer Case Problem

[TMarsala]

I have a 2005 4X4 Dodge Ram Automatic, I went to drain the transfer case, and what I thought was the drain plug turned out not to be the drain plug.

The plug I removed had a bullet shaped sleeve with a small hole at the pointed end and a spring popped out. After this all came out some fluid followed, but not quite the amount I imagined.



After the fluid stopped coming out I removed the fill plug and put 1 QT of Universal Tramission fluid from amsoil in.



When I tried to go into 4 wheel drive the shift lever would not engage and kept popping out of 4 wheel. I'm now sure that the way I put the spring and sleeve back together has something to do with this.



I reinstalled the bullet shaped sleeve pointed side down in the drain plug and then put the spring into the sleeve and tightened it down.



I need advice as to what to do to correct this problem and what the heck is the plug that I did pull.



I appreciate all the help I can get to this problem... .



Tom

 

[HOBrian]

That spring is the "shift detent spring". Was this bolt that you removed on the opposite side of the drain plugs??? (meaning motor side of TC housing) If yes then this is you detent spring and will give you the problem you have.



The service manual says that you have to install in this order:

1. Plunger

2. Spring

3. Detent plug

4. torque to 12-18 ftlbs.



Don't forget the O-ring.

I hope this helps

 

[TMarsala]

Brian

Yes you have it right, sounds exactly like you mentioned. I don't remember seeing an O ring, where would that go? I put it together wrong and never saw an O ring, would I have a leak it I didn't have it, because I don't have a leak.



Also was wondering when I put it together as you mention will it go straight up and should I feel like it's engaging with something, or will it just go in and I will not feel anything special. In the event, I don't see an O ring when I take it apart is this something I have to get at a dealer?



Thanks for your help much appreciated...

 

[HOBrian]

The o-ring is on the bolt to keep fluid from leaking. I am guessing it is still on the bolt. I do not know how it should feel going back together. Try the oder I wrote and see if it gets better. Oo.

 

[TMarsala]

Brian, thanks for all the info, it's much appreciated... BTW, I use to live in NJ, Cedar Grove. Don't know if you know the area or not... .



I'll try pulling it apart and re-installing... Hope this message saves someone else the hassle I had...



Tom

 

[HOBrian]

I live in Oakland. I hope all goes well!Oo.

 

[TMarsala]

I removed the spring only to find it bent from trying to put 4X4 in gear, after getting it as straight as possible I reassembled it the correct way and it works great now. I called my local dealer for availabilty of the o-ring just in case I needed a new one, they wanted $9. 00 I just can't believe a . 25 cent part they are getting $9. 00 for. I can just imagine if I need to get the spring replaced because I couldn't straighten it, that might go for $25. 00.



Thank you, for all your help... .

 

[HOBrian]

No problem!!! This is why this site is great, well worth the 35 bucks!!!!!