Bought my 2nd 2010 Rallye AWD with V6 that was also in need of repair, the 1st one I had to replace the V^ and I dropped in a 4.0 out of a Pacifica, changing oil pan-intakes-timing cover and installing new timing set, replaced starter since easy access and was already out.
This 2nd one was making loud noises when put in gear, the spline coupler that resides inside the extension housing between the Nag1, 722.6, transmission and the Borg Warner 44-40 transfer case, which only gets a thin grease coating, had lost its grease, rusted, and the splines wore off eating both the coupler, they call it a flange package, and the input shaft of the transfer case.
Mopar, in all its wisdom, discontinued both the coupler and the input shaft for the transfer case and relies on 3rd part vendors to make the parts, which none have taken the challenge...
I reached out to every Hard Part supplier listed in the Transmission Digest, some monthly publication, and 1 reached back to me and supplied me a usable part with minimal wear that will work, when I can find a new case without spline wear. They only used this design on very late 08s and 09-10s and not enough had issue, but all stock of new was used up, so they were wrong.
Uploading this so I can share to the Charger Forums, and provide information to those who may have this issue.
5143239AB or 5153239AA are the couplers discontinued, if you have one people, I will buy a spare...
The 2 transfer cases available were the 04593838AC, which has the input shaft discontinued, 68055266AA, and case 68088811AA, which uses 68101736AA, still available, but no clue on what the difference may be.
The listing for the front bearing is the only difference and the 2nd case uses a heavier bearing, so possibly just a wider bearing surface machined into shaft?? With rest of the parts the same, what else could it be? If you know, please let us know..