how to fix Ram 1500 DT (2019-Present) transfer case problems

Solution

1. Preparation

• Tools Required: Socket set, torque wrench, OBD-II scanner, multimeter, fluid pump.
• Disconnect the battery to ensure safety during the repair process.
• Allow the vehicle to cool down if it has been running.

2. Fluid Replacement

• Sub-steps:
  1. Place a drain pan under the transfer case to catch old fluid.
  2. Remove the drain plug using a socket set and allow the fluid to fully drain.
  3. Inspect the old fluid for metal shavings or contaminants, which may indicate internal damage.
  4. Clean the drain plug and replace the sealing washer if necessary.
  5. Reinstall the drain plug and torque it to the manufacturer's specifications (typically around 25 ft-lbs).
  6. Use a fluid pump to fill the transfer case with new transfer case fluid, ensuring it meets the specifications provided in the owner's manual.

3. Inspect and Replace Shift Motor

• Sub-steps:
  1. Remove the shift motor assembly from the transfer case using a socket set.
  2. Inspect the gear teeth and electrical connections for wear or damage.
  3. If damaged, replace the shift motor with a new unit.
  4. Reinstall the shift motor, ensuring proper alignment and torque the fasteners according to specifications.
  5. Reconnect the electrical connector securely.

4. Verify Linkage and Adjustments

• Sub-steps:
  1. Inspect the shift linkage for wear and proper alignment.
  2. Adjust or replace any misaligned or damaged linkage components.
  3. Ensure that the linkage allows for smooth engagement between 2WD and 4WD.