Parts for New Process NP241DHD Transfer Cases in 1994-1997 Dodge Ram 2500 & 3500 4x4 Trucks
We stock a full line of original equipment parts for the New Venture NP241DHD Transfer Cases used in 1994 to 1997 Dodge Ram 2500 and Ram 3500 4x4 trucks. Also see our 1998-2002 NP241DHD, 1994-1997 NP241DLD, and 1998-2002 NP241DLD web pages.

The NP241DHD differs considerably from earlier NP241D transfer cases used from 1987 to 1993 and the second generation NV241D introduced for the 2002 Ram 1500. Starting in 1994, the stock Ram 2500 transfer case was the NV241DLD (Dodge Light Duty). Optional on the Ram 2500 and standard on the Ram 3500 was the NV241DHD (Dodge Heavy Duty). There were numerous design changes in the NP241DLD/DHD during its production life;  making part(s) selection a bit tricky without the round transfer case build tag affixed to the rear case half.

Despite the many assembly variations, there are a few common characteristics shared by both DLD and DHD models. All these cases will have a slip yoke rear output, left drive chain front output, with CV flange and mechanical shift engagement.  The cases will  also have a 6-gear planetary 2.72:1 ratio low range, and a transfer case mounted vacuum switch, which controls the front axle disconnect system. (continued below)

Bearing and Master Overhaul Kits

 

 

 

 


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 TK2500CDHDE Torque King® Master NP241 Overhaul Kit is the absolutely highest quality and most complete NP241DHD transfer case overhaul kit available for your 1994-1997 Dodge Ram 2500 or Dodge Ram 3500 4x4 truck bar none. Kit includes Original Equipment and U.S.A. made ball bearings (Rear output bearings on late model cases with one piece tailshaft housing and wide input bearings for current production use imported genuine original equipment replacement parts). This kit also includes Torrington straight roller bearings, planetary thrust washers, Morse® drive chain, all snap rings, o-rings, shift fork pads, main housing to tail housing shim gasket, tailshaft housing bushing, oil pump hose, oil pump screen and original equipment quality seal. In addition it contains, spline seal, front output nut, RTV sealant, and threadlocker. Each kit is custom tailored for your specific NP241DHD transfer case from original equipment parts lists. Mostly Made in U.S.A. Some components imported

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Bearings
Click to Enlarge QU50176 Wide Input Ball Bearing is used on some 1994 to 1997 Dodge Ram 2500 and Ram 3500 4x4 trucks with NP241DHD Transfer Cases (See Tech Note Below). Includes snap ring installed in outer race groove. This current production, genuine original equipment bearing is imported. If used in your Transfer Case, this part is included in our application specificTK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU50176 page for more details and ordering information.

Dan the Gear Man Tech Note: For the 1994 to 1997 model years, New Process built NP241DHD Transfer Cases with two different, non-interchangeable Input Bearing widths. You need to either supply us with the build tag number along with the engine/transmission combination or physically verify if this bearing or QU50158 shown below is the correct bearing for your input shaft.
Click to Enlarge QU50158 Narrow Input Ball Bearing is used on some 1994, 1995, 1996, and 1997 Dodge Ram 2500 and Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Includes snap ring installed in outer race groove. Made in U.S.A. If used in your Transfer Case, this part is included in our application specificTK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU50158 page for more details and ordering information.

Dan the Gear Man Tech Note: For the 1994 to 1997 model years, New Process built NP241DHD Transfer Cases with two different, non-interchangeable Input Bearing widths. You need to either supply us with the build tag number along with the engine/transmission combination or physically verify if this bearing or QU50176 shown above is the correct bearing for your input shaft.
Click to Enlarge QU50114 1 Piece Mainshaft Front Pilot Bearing and Cup original equipment, unitized drawn cup bearing replaces QD10000 Bearing and QU50083 Sealing Plug. The one piece design of this bearing simplifies installation. Both this bearing and the QD10000/QU50083 combo were used in original equipment applications and they are functionally interchangeable on all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. This Bearing fits in the back of the input shaft to support the front of the mainshaft (rear output shaft) Made in U.S.A. This part is included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU50114 page for more details and ordering information.
QD10000 Optional, Heavy-Duty Mainshaft Front Bearing is used with QU50083 Plug. Both the QD10000/QU50083 combo and QU50114 1 Piece bearing were used in original equipment applications and are functionally interchangeable on all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. This Bearing fits in the back of the input shaft to support the front of the mainshaft (rear output shaft) Made in U.S.A. Order QU50083 Sealing Plug below.

Please refer to QD10000 page for more details and ordering information.
QU50157 Output Ball Bearing One or two of these Bearings will be used in each 1994 to 1997 NP241DHD Transfer Case depending upon the rear output configuration. QU50157 is always used as the NP241DHD front output bearing. It is also used as the rear output bearing on those 1994 to early 1997 NP241DHD models with the two piece tailshaft housing and QU10968 32 spline rear output shaft. For front output applications, this bearing gets pressed in the front output bearing bore machined in the front transfer case half and is secured with QU10874 Snap Ring. Made in U.S.A. This part is included in ourTK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU50157 page for more details and ordering information.
QU50207 Rear Output Bearing for NP241DHD with One Piece Rear Extension Housings for all 1996-1997 NP241DHD Transfer Cases with QU50523 31 Spline rear output shafts. QU50207 is located on the mainshaft by 2 QU10817 snap rings. It is secured in the tailshaft housing by QU10815 Snap Ring which fits the groove in the outer race. This genuine original equipment bearing is imported. This part is included in ourTK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU50207 page for more details and ordering information.

QU50502 Front Output Rear Bearing made in U.S.A. for all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. This original equipment caged needle roller bearing gets pressed in the front output bearing bore machined in the rear transfer case half. For heavy duty applications, see optional QU10879 below. As an option, you can upgrade this bearing to QU10879 Heavy Duty bearing listed below. Made in U.S.A.

Please refer to QU50502 page for more details and ordering information.
QU50201 NP241DHD Planetary Bearing for all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. This bearing, which supports QU11047 or QU50150 Range Sleeve is pressed in the Planetary Set. Made in U.S.A. This part is included in ourTK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU50201 page for more details and ordering information.
Click to Enlarge QU10879 Optional, Heavy-Duty, Full Complement Front Output Rear Bearing for all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. This max capacity, needle roller bearing has over 30% more needle rollers than the original equipment type QU50502 bearing which helps minimize deflection of the front output shaft under extreme loads. This bearing gets pressed in the front output bearing bore machined in the rear transfer case half. Made in U.S.A. This part is included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU10879 page for more details and ordering information.
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Bushings
Clcik to Enlarge QU10130 Small Bore Genuine New Process Rear Output Bushing

Please refer to QU10130 page for more details and ordering information.

QU90025 Large Bore Genuine New Process Rear Output Bushing fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Your driveshaft slip yoke will be approximately 2-3/16"" in diameter. Made in U.S.A. This part is included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU90025 page for more details and ordering information.

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Case Halves
QU50591 Dodge NP241DHD Front Case Half

for most 1994 to 1997 Dodge Ram 2500 and Ram 3500 4x4 trucks with NewProcess NP241DHD Transfer Cases.

 
QU50344 Rear Case Half is a genuine New Process Gear replacement part for all 1994-1997 New Process NP241DHD Transfer Cases. These brand new housings include a pre-installed QU50502 Front Output, Rear Needle Bearing.QU50344 Rear Case Half fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.

Please refer to QU50344 page for more details and ordering information.
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Case Parts
QU50422 NP241DHD One Piece Rear Extension Housing fits late 1996 and 1997

NP241DHD Transfer Cases with QU50523 31 spline output shafts.

Please refer to QU50422 page for more details and ordering information.
  QU50419 New Process NP241DHD Transfer Case Rear Bearing Housing is a genuine New Process part for 1994 to 1996 Dodge Ram 2500 and Ram 3500 4x4 trucks with NP241DHD Transfer Cases and 32 spline rear output shafts.
QU10189 1994-1996 NP241DHD Rear Extension Housing for 1994-1996 Dodge New Process NP241DHD Transfer Cases with QU10968 32 spline output shafts


QU50501 Input Bearing Retainer is a genuine original equipment part. Due to numerous design changes in the molds used over the years, this new retainer may look different than your original retainer, but it will directly replace your damaged or broken retainer on all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.

Please refer to QU50501 page for more details and ordering information.
Click to Enlarge QU70005 6 Bolt PTO or Inspection Cover

New takeout covers from new units we have disassembled for parts. For all NP241DHD Transfer Cases.

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QK1000 Manual Transmission or Transfer Case Filter Kit   Includes:  Filter Housing and Plate, 2 Filter Elements, 1 Cork Gasket, 1 Paper Gasket with Sealing Ring, 2 Class 35 Rare Earth magnets, and RTV sealant.  Made in U.S.A.

Please order your QK1000 Manual Transmission or Transfer Case Filter Kit from our Filter Kits Web Page.
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Drive Chains
Transfer Case Drive Chains  Need a new drive chain for your transfer case? We stock premium quality Morse Hy-Vo® original equipment replacement chains. The best quality chain available for your transfer case. Genuine U.S.A. Made Morse Chains Made in U.S.A.

Transfer Case Drive Chain Applications for Ram chargers and Full Size 1/2 ton, 3/4 ton, and 1 ton pickups:
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QU50000 Drive Chain 1½" wide Genuine Morse original equipment transfer case drive chain fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. This part is included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU50000 page for more details and ordering information.

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Input Shafts
Dodge used a total of eight different input shafts in NP241DLD transfer cases for the 1994 to 1997 model years. The differances included spline size, length, gear tooth profile and bearing thickness. We stock the most popular NP241DLD input shafts including three 29 spline and three 23 spline inputs.

Dan the Gear Man Tech Note: If you are unsure of what Input Shaft you need, or you are doing a transmission swap requiring a different spline Input, you MUST provide us with the year, engine, transmission, 8 digit Assembly number begining with 5209 or 5210 found on the round ID tag affixed to the back case half, plus the spline count and overall length of your input shaft!

 Link to Our Dodge Web Page Index

QU50637 1994-1996 23 Spline Input Shaft uses QU50176 Wide Input Bearing. This USA made, genuine New Process original equipment replacement part fits Dodge NP241DHD Transfer Case assembly number 52105091 and 52098677.

QU50638 1994-1997 23 Spline Input Shaft uses QU50158 Narrow Input Bearing. This USA made, genuine New Process original equipment replacement part fits Dodge NP241DHD Transfer Case assembly numbers 52105335 and 52105513.

QU50639 1994-1996 23 Spline Input Shaft uses QU50176 Wide Input Bearing. This USA made, genuine New Process original equipment replacement part fits Dodge NP241DHD Transfer Case assembly number 52099036.

Click to Enlarge QU10699 29 Spline Input Shaft uses QU50158 Narrow Input Bearing. This USA made, genuine New Process original equipment replacement part includes QU50114 1 Piece Mainshaft Front Pilot Bearing and Cup pre-installed in the back of the center bore.  Fits Dodge 1996-1997 NP241DHD Transfer Case assembly numbers 52105092 and 52105314.


Click to Enlarge QU10889 29 Spline Input Shaft uses QU50176 Wide Input Bearing. This USA made, genuine New Process original equipment replacement part includes QU50114 1 Piece Mainshaft Front Pilot Bearing and Cup pre-installed in the back of the center bore. Fits Dodge 1996-1997 NP241DHD Transfer Case assembly numbers 52098512 and 52098678.

QU50477 29 Spline Input Shaft for 1994-1996 NP241 Transfer Cases with First Design Planetary Teeth uses QU50176 Wide Input Bearing. Imported. Order either QU50083 Sealing Plug plus QD10000 Mainshaft Pilot Bearing OR QU50114 One piece unitized Pilot Bearing/Cup separately. Fits Dodge 1994-1997 NP241DHD Transfer Case assembly number 52098534
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Miscellaneous

 
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Click to Enlarge

QU11044 Trans Plug

Please refer to QU11044 page for more details and ordering information.
Click to Enlarge QU10569 Central Axle Disconnect (CAD) Vacuum Switch screws into the front case half, above the internal shift cam on all 1994, 1995, 1996, and 1997 Dodge Ram 2500 and Dodge Ram 3500 trucks with vacuum controlled Central Axle Disconnect (CAD) front drive axles.

Please refer to QU10569 page for more details and ordering information.
TK10586 Transfer Case Rear Housing Shim Gasket with Seal Ring is a genuine New Process Gear original equipment, dual function part that both seals and properly spaces the tailshaft extension housing from the rear case half. The raised rubber ring provides a leakproof seal and the precision thickness of the metal shim gasket controls the location of the mainshaft which minimizes the chances for premature shift fork and bearing failures. Made in U.S.A. This part is included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to TK10586 page for more details and ordering information.
Click to enlarge QK2069 Transfer Case Saver Kit for all New Process 231 and 241 Transfer Cases with the 2 piece tailshaft which uses 4 bolts to attach the extension housing to the tailshaft housing. Replaces the failure prone factory snap ring that holds the rear output shaft against the rear output bearing. Easy to install, patented design part includes two precision machined rings that bolt together, two bolts, threadlocker, & RTV sealant. Made in U.S.A.

*Will not work on transfer cases with either the 3 bolt rear extension piece or any models with the 1 piece tailshaft housing. This includes MOST 1997 241DHDs' and any 1994-1996 241DHD model with the 2.2" diameter output yoke!*

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Oil Pumps and Oil Pump Pickup Parts
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 QU10673 Oil Pump Hose connects the QU10674 Oil Pickup Filter Screen to QU10823 Oil Pump Feed Tube on your NP241DHD Transfer Case. This genuine New Process Hose has the correct flexibility and oil resistance needed for long life. QU10673 Oil Pump Pickup Connector Hose fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases.  Made in U.S.A.

Dan the Gear Man® Tech Note: If you don't want to risk burning your Transfer Case up, don't replace this little guy with inexpensive fuel line hose or similar products.  You risk a cracked hose which will lead to oil pump and mainshaft failure.
Click to Enlarge QU10674 Oil Pickup Screen is a genuine New Process Gear replacement part. Your Oil Screen is located in the bottom of the case just above the chip magnet. The plastic screen filters out chips and crud from the oil before it gets to the pump. QU10674 Oil Pump screen fits all 1998, 1999, 2000, 2001, and 2002 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1998, 1999, 2000, 2001, and 2002 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.
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 QU10802 Oil Pump Feed Tube to Oil Pump O-Ring seals the connection between your QU10936 oil pump and QU10823 Oil Pump Feed Tube. QU10802 Oil Pump O-Ring fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Imported.

QU10823 Oil Pump Feed Tube is used to transfer oil from the QU10674 Pickup Screen to QU10936 Oil Pump. Genuine original equipment part. QU10823 Oil Pump Tube fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD Transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.

Dan the Gear Man® Tech Note: You will often find original Pickup Tubes worn from slapping against the cases that keep it from flopping around. If your Pickup Tube is damaged, REPLACE IT!  It is crazy to chance wrecking your transfer case due to oil starvation!

QU10936 Oil Pump for 31 Spline Dodge NP241DHD Transfer Cases is a genuine, original equipment New Process Gear replacement part. Pre-assembled, 31 spline pump includes QU50177 Oil Pump Seal. QU10936 Transfer Case Oil Pump fits 1996-1997 NP241DHD Transfer Case with 31 Spine Rear Output Shafts. Order QU10802 O-ring separately. Made in U.S.A.
QU50423 Oil Pump for 32 Spline Dodge NP241DHD Transfer Cases is a genuine, original equipment New Process Gear replacement part. Pre-assembled, 32 spline pump includes QU50177 Oil Pump Seal. QU50423 Transfer Case Oil Pump fits 1994-1996 NP241DHD Transfer Case with 32 Spine Rear Output Shafts. Order QU10802 O-ring separately. Made in U.S.A.
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O-Rings
Click to Enlarge QU10824 Sector Shaft Outer Seal protects QU10825 Sector Shaft Inner O-Ring from road splash and grit. This genuine New Process Gear plastic Sector Shaft (Shift Cam) Outer Seal fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A. This part is included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU10824 page for more details and ordering information.
Click to Enlarge QU10825 Sector Shaft Inner O-Ring Sector Shaft Inner O-Ring seals the Sector (Shift Cam) Shaft to keep oil in and water out. QU10825 Sector Shaft (Shift Cam) Shaft O-Ring fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Imported. This part is included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU10825 page for more details and ordering information.
Click to Enlarge QU10800 Poppet Plug or Vacuum Switch to Case O-Ring Two of these O-Rings are used on each NP241DHD Transfer Case. Use one O-Ring to seal QU11016 Poppet Plug and one to seal QU10569 Vacuum Switch. QU10800 Poppet or Switch O-Ring fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Order two per transfer case. Imported. Two of these O-Rings are included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to to QU10800 page for more details and ordering information.
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Output Flanges and Yokes
QK2006 Front Output Flange Kit for fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks. Kit includes QU50043 Output Flange, TK10513 Spline Seal, QU10512 Flange Nut, QU10646 Slinger, QU40366 Seal, and Threadlocker. Order QU10806 Bolts to secure driveshaft.
QU40498 Slip Yoke Assembly with Dampener for 1994 to 1996 NP241DHD Transfer Cases with 32 spline output shafts.
QU40472 Slip Yoke without Dampener for 1994 to 1996 NP241DHD Transfer Cases with 32 spline output shafts.

 
QU40700 Slip Yoke without Dampener for 1996-1997 NP241DHD Transfer Cases with 31 Spline Rear Output Shafts.
QU40499 Slip Yoke Assembly with Dampener for 1996-1997 NP241DHD Transfer Cases with 31 Spline Rear Output Shafts.

QU50043 Front Output CV Flange Yoke is a genuine original equipment replacement part for all 1994 to 1997 HP241DHD Transfer Cases.
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Output Shafts
QU10968 32 Spline 241DHD Rear Output Mainshaft is a genuine New Process Gear replacement shaft

for early version NP241DHD models that have the 1-3/8" x 32 spline output shaft instead of the larger QU50523 1-5/8" 31 spline shaft used on late 1996 and all 1997 NP241DHD transfer cases with assembly numbers beginning with 5210.

$432.97 or Save 3% by purchasing Online for only $419.97


QU50523 31 Spline NP241DHD Rear Output Shaft (Mainshaft) is a genuine New Process Gear replacement shaft for 1996 and 1997 NP241DHD models that have the 1-5/8" x 31 spline output shaft instead of the earlier QU10968 1-3/8" 32 spline shaft used on 1994 to 1997 NP241DHD transfer cases with assembly numbers beginning with 5209 (may be some early 1997 transfer cases with QU10968 1st design shaft).

Please refer to QU50523 page for more details and ordering information.

QU10200 Front Output Shaft for NP241DHD Transfer Cases is a genuine New Process Gear replacement part that fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.
$62.05 or Save 3.5% by purchasing Online for only $59.95


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Planetary Assemblies
Click to enlarge QU50494 6 Pinion Planetary Carrier for 241DHD Transfer Cases includes the PTO drive gear and installed Bearing. A genuine original equipment New Process Gear replacement assembly with 6 pinion gears. QU50494 NP241DHD Planetary fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. USA Made Genuine Original Equipment Part. Made in U.S.A.
$442.87 or Save 3% by purchasing Online for only $429.97

 
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Poppet Parts
Click to Enlarge QU10800 Poppet Plug or Vacuum Switch to Case O-Ring Two of these O-Rings are used on each NP241DHD Transfer Case. Use one O-Ring to seal QU11016 Poppet Plug and one to seal QU10569 Vacuum Switch. QU10800 Poppet or Switch O-Ring fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Order two per transfer case. Imported. Two of these O-Rings are included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to to QU10800 page for more details and ordering information.
Click to Enlarge QU11016 Poppet Plug is a genuine, original equipment New Process Gear replacement part and it includes QU10800 O-Ring. QU11016 Poppet Plug fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.

Please refer to QU11016 page for more details and ordering information.
Click to Enlarge QU11027 Poppet Spring is a genuine original equipment New Process Gear compression type spring that directly replaces your weak or broken Poppet Spring and restores positive engagement Poppet Plunger and Shift Cam Plate. QU11027 Poppet Spring fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.

Please refer to QU11027 page for more details and ordering information.
Click to Enlarge QU11018 Poppet Plunger is a genuine New Process gear replacement part. Not a common part to fail, but when the tip wears, the transfer case will have a tendency to jump out of gear. QU11018 Poppet Plunger fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.

Please refer to QU11018 page fro more details and ordering information.
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Seals
Click to Enlarge QU10857 Genuine New Process Input Seal replaces earlier designs on all 1994-1997 Dodge NP241DHD series Transfer Cases. Seal features raised rubber outer sealing ring to seal against retainer chamfer and high-temp resistant Viton seal lip with outer wiper.  QU10857 INP241DHD Input Seal fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. USA Made Genuine Original Equipment Part. Genuine New Process part is Made in Taiwan This part is included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU10857 page for more details and ordering information.
QU50177 Genuine New Process Oil Pump Seal is an exact original equipment manufacturer replacement Seal. QU50177 Oil Pump Seal fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A. or Mexico This part is included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU50177 page for more details and ordering information.
Click to Enlarge QU10610 Booted Rear Output Seal is a genuine USA made New Process part for all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases with a slip yoke that is approximately 1-7/8" in diameter.

Please refer to QU10610 page for more details and ordering information.
QU50171 Booted Rear Output Seal fits all 1994-1997 NP241DHD Transfer Cases which all have a slip yoke that is approximately 2-3/16" in diameter. QU50071 Rear Output Seal fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. USA Made Genuine Original Equipment Part. Made in Mexico This part is included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU50171 page for more details and ordering information.
QU40366 Flanged Front Output Seal for all 1994-1997 Dodge NP241 series Transfer Cases. Made in Mexico

Please refer to QU40366 page for more details and ordering information.

Dan the Gear Man® Tech Note: This is the seal I prefer to use over the original New Process Seal because the flanged design is easier to install and remove, plus setting the seal depth is fool-proof, unlike the OE design that requires the seal being precisely installed of a depth of no less than 0.080" deep, but no more than 0.100"deep.
NP205 32 Spline Yoke and Shaft SealClick to Enlarge TK10513 Spline Seal for 32 Spline Output Shafts and Remote Mount Input Shafts is approximately 0.182" thick with 32 splines and is the best fit for NP205 early front output shafts using standard yokes, rear output shafts, and remote mount input shafts. Use with yokes that are retained by a washer and nut. Made in U.S.A.

Please refer to TK10513 page for more details and ordering information.
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Shift Forks and Shift Hubs
Shift Forks are genuine New Process/New Venture components for maximum durability and precise fit. Shift fork tip wear is fairly common in 205 and 241 transfer cases.  241 forks that need replacement are often the victim of low/improper lubrication, broken snap rings, or bearing wear.  Early 241 Range Forks have replaceable fork pads;  late ones have molded, non-replaceable pads. 

Range Forks are one of the most common hard parts requiring replacement in NP241 series transfer cases. New Process used two different range forks in 1994-2002 241 series transfer cases making it a bit more difficult to pre-order a fork prior to transfer case disassembly unless the transfer case tag number or year is positively known.
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Click to enlarge		 QU50144 Cast Iron Range Fork Genuine New Process original equipment Range Fork fits all 1994-1997 Dodge NP241DLD and NP242DHD Transfer Cases.

Please refer to QU50144 page for more details and ordering information.
Click to Enlarge QU10929 Mode Fork and Rod (no pads) Genuine USA made Cast Iron Mode Fork with Shift Rod fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.

Please refer to QU10929 page for more details and ordering information.

If you need pads, order 2-QU10164 and 1-QU10574 below.
QU50150 Sleeve fits all 1994-1997 NP241DHD Transfer Cases QU50150 Range Fork Sleeve is a genuine New Process original equipment replacement part. Made in U.S.A.
$242.05 or Save 3% by purchasing Online for only $235

Dan the Gear Man® Tech Note: NP241DHD Range Fork Sleeves are subject to wear in three places: The clutch teeth, Bearing Surface, and Hub/Snap ring area. Of the three, the most likely problem area is where QU50151 Hub fits. It is not uncommon to find the shoulder, hub surface, and snap ring groove chewed up. There can be several causes including lubrication issues, Mainshaft snap ring failures, and Range Fork (QU50144) wear.

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QU50151 Fork Hub is one of the most common NP241DHD hard parts needing replacement in cases where the transfer case is jumping out of gear or there are lubrication problems. QU50151 Shift Fork Hub rides on the Range Sleeve QU50150. It is retained by QU50080 Snap Ring. Genuine New Process Gear original equipment replacement part. QU50151 Shift Fork Range Hub fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.
$98.33 or Save 3.5% by purchasing Online for only $95


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Shift Parts
Click to Enlarge QU10589 Shift Linkage Grommet for either end of the transfer case shift rod that connects your floor-mounted shift lever with the transfer case. Genuine original equipment New Process Gear replacement part. Requires 2 Bushings per vehicle. QU10589 Shift Linkage Grommet fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A. Two of these parts are included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU10589 page for more details and ordering information.

May be either green or black in color

Click to Enlarge QU10164 Mode Fork Shift Pad fits the tips of all QU10929 1994-1997 Dodge 241DHD series Mode Forks. These genuine, original equipment New Process gear pads are tough and durable. Requires 2 per Fork. QU10164 Range Fork Tip Pad fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.  Two of these parts are included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU10164 page for more details and ordering information.

Dan the Gear Man® Tech Note: Unlike most aftermarket pads, these original equipment parts are not brittle or subject to premature wear and breakage.  We see durability problems with aftermarket shift fork pads for virtually all 4x4 transmission and transfer case applications.
Click to Enlarge QU10574 Mode Fork Center Pad.  fits the tips of all QU10929 1994-1998 Dodge 241DHD series Mode Forks. These genuine, original equipment New Process gear pads are tough and durable. Requires 2 per Fork. QU10164 Range Fork Tip Pad fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.  Two of these parts are included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU10574 page for more details and ordering information.

Dan the Gear Man® Tech Note: Unlike most aftermarket pads, these original equipment parts are not brittle or subject to premature wear and breakage.  We see durability problems with aftermarket shift fork pads for virtually all 4x4 transmission and transfer case applications.
Click to Enlarge QU10875 Range Fork Center Shift Pad for 1994-1997 Dodge NP241 series Transfer Cases.  This Pad fits only fits Cast Iron Forks.

Please refer to QU10875 page for more details and ordering information.

*Will Not fit 1998-2002 aluminum Range Fork*
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Slingers
     

Click to enlarge		 QU10646 Slinger for all 1994-1997 Dodge NP241DLD and NP241DHD Transfer Cases

Please refer to QU10646 page for more details and ordering information.
     
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Small Parts
     

Click to enlarge		 QU10587 NP241DHD Transfer Case Access Plug is a genuine New Process piece that seals the Snap Ring Access Slot in all 1994-1997 NP241DHD Transfer Cases. QU10587 Plug fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. This part is included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU10587 page for more details and ordering information.
Click to Enlarge QU10512 Front Output Nut fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A. This part is included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU10512 page for more details and ordering information.

Click to enlarge		 QU10572 Input Shaft to Planetary Thrust Washer Two of these genuine New Process Gear original equipment Thrust Washers are used between the Input Gear and Planetary Assembly. QU10572 fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A. Two of these parts are included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU10572 page for more details and ordering information.
Click to enlarge QU50083 Sealing Plug for Input Shafts is used with QD10000 optional Mainshaft Pilot Bearing to prevent oil from leaking through the inside of the Input Shaft. QU50083 fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Country of origin not known.

Please refer to QU50083 page for more details and ordering information.

QU10971 Transfer Case Mounting Stud
     
     
     
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Snap Rings
  Our Snap Rings are Listed in three groups. Those that fit all 1994-1997 NP241DHD models are in the first section, those that ONLY fit 32 Spline Rear Output Shafts are in the second section, and the last section is for those rings that only fit 31 Spline Rear Output Shafts. Dodge used two versions of NP241DHD Transfer Cases for the 1994-1997 model years. While many of the Snap Rings are the same for both 31 and 32 spline versions, the Snap Rings for the output shafts themsleves are different. The small, 32 spline rear output shaft will be found on 1994-1996 transfer case assembly numbers begining with 5209 and the Extension Housing is a two piece type. The large 31 spline rear output shaft will be found on 1996-1997 Transfer Cases with assembly numbers that begin with 5210 and one piece Extension Housings.  
  Section 1: Snap Rings That Fit ALL 1994-1997 Dodge NP241DHD Transfer Cases  
QU10893 1994-1997 Dodge NP241DHD Transfer Case Input Shaft to Bearing Snap Ring fits in the snap ring slot machined in your input shaft and it is installed after your push the shaft through the Input Bearing. For all 1994-1997 NP241DHD models.
QU10814 Planetary Snap Ring for ALL 1994-1997 Dodge NP241DHD Transfer Case secures the Input Shaft and Planetary Thrust Washers inside QU50494 Planetary Assembly.
QU10872 Synchro Hub to Mainshaft Snap Ring for ALL 1994-1997 Dodge NP241DHD Transfer Cases is used to hold the Synchronizer Hub in place on the Mainshaft.
QU50080 241DHD Range Fork Hub to Range Sleeve Retaining Ring for ALL 1994-1997 Dodge NP241DHD Transfer Cases holds QU50151 Shift Fork Hub on either QU50150 Range Sleeves.
QU10820 Synchronizer Strut Tension Spring for ALL 1994-1997 Dodge NP241DHD Transfer Cases Two of these springs are used in each NP241DHD to apply tension to the three QU10821 Synchro struts or keys.

QU10874 Front Output Shaft Bearing to Front Case Snap Ring for ALL 1994-1997 Dodge NP241DHD Transfer Cases is used to lock QU50157 Front Output Shaft Front Bearing in place in the front case half.

QU10818 Lower Sprocket to Front Output Shaft Snap Ring fits in a groove machined in QU10200 Front Output Shaft to secure QU10922 Driven Sprocket in place.
  Section 2: Snap Rings That ONLY FIT 1994-1996 32 Spline Rear Output NP241DHD Transfer Cases  
Click to Enlarge QU10873 Speedometer Retaining Snap Ring for all 1994-1996 Dodge NP241DHD Transfer Cases with 32 Spline Rear Output Shafts

 
QU10816 Rear Output Shaft to Rear Output Bearing Snap Ring for 1994-early 1997 NP241DHD Transfer Cases with twp piece rear tailshft housings and 32 spline rear output shafts.
  Section 3: Snap Rings That ONLY FIT 1996-1997 31 Spline Rear Output NP241DHD Transfer Cases  
QU10815 Rear Output Bearing to Case Snap Ring for 1996-1997 Dodge NP241DHD Transfer Cases with 1 piece Tailshaft housings and 31 spline rear output shafts.  This Ring is placed in the Tailshaft Housing groove and expanded as the housing is lowered over the output shaft until it line up with the groove in QU50207 output bearing. Your Transfer Case will have a 1 piece tailshaft housing and a 2.2" slip yoke diameter.
QU10817 Rear Output Shaft Snap Ring for 1996-1997 NP241DHD Transfer Case with 31 Spline Rear Output Shafts Two of these Snap Rings are used to center QU50207 Rear Output Bearing to the Mainshaft and two are used to secure the speedometer drive gear.
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Speedometer Parts
     
Click to Enlarge QU10678 O-Ring, Speedometer Output. This o-ring seals between the 2" speedometer output carrier and the tailshaft housing on all Dodge NP241 Transfer Cases through the 1997 model year. Imported

Please refer to QU10678 page for more details and ordering information.
Click to Enlarge QU10873 Speedometer Retaining Snap Ring for Dodge all NP241DLD and 1994-1997 Dodge NP241DHD Small Shaft Transfer Cases

Please refer to QU10873 page for more details and ordering information.
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Sprockets
There typically is no reason to replace the sprockets on Dodge NP241DLD and NP241DHD Transfer Cases unless, the unit had either lubrication issues or an extremely worn chain. But, if you do need one or both sprockets, we have genuine, USA made, original equipment New Process Sprockets in stock. These American made parts are not cheap, but the accuracy, metal quality and precision machining of these genuine NPG sprockets is first class and far superior to cheap offshore imitations sold by others.
Click to Enlarge QU10921 Upper Chain (Drive) Sprocket for Dodge NP241DHD Transfer Case is a genuine New Process Gear original equipment replacement part. Not a common part to replace unless the chain is badly worn or there has been lubrication issues which will cause galling on the precision machined bearing bore. QU10921 Upper Chain Drive Sprocket fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.
$423.97 or Save 2% by purchasing Online for only $414.97


QU10922 Lower Chain (Driven) Sprocket for Dodge NP241DHD Transfer Case is a genuine New Process Gear replacement part. In most cases sprocket replacement is not needed, but if you can see and feel any wear marks from the chain links, you must replace the sprocket(s) to prevent premature failure of a new chain. QU10922 Lower Driven Chain Sprocket fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.
$82.77 or Save 3.5% by purchasing Online for only $79.97


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Synchronizer Parts
     
Click to Enlarge QU10820 Synchronizer Strut Tension Spring Two of these genuine NPG springs are used in each NP241DHD to apply tension to the three QU10821 Synchro struts or keys. QU10820 Synchro Tension Spring fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A. Two of these parts are included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU10820 page for more details and ordering information.
Click to Enlarge QU10821 Synchro Strut Three of these genuine original equipment New Process Gear Struts or Keys are used in every NP241DHD Transfer Case to transfer tension from QU10820 Spring to QU50354 Synchronizer Sleeve. Made in. U.S.A. Three of these pars are included in our TK2500CDHDE NP241DHD Master Overhaul Kit shown at the top of this page.

Please refer to QU10821 page for more details and ordering information.
Click to Enlarge QU10819 Ring is a genuine New Process Gear Replacement Part. Since most people do not use 4x4 all that often, wear is not usually an issue with these Blocking Rings, but of course some will need to replaced for one reason or another. The tapered inside of the ring fits a matching taper on QU10921 Upper Sprocket. QU10819 Synchronizer Blocking Ring fits all 994, 1995, 1996, and 1997Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.

Please refer to QU10819 page for more details and ordering information.
Click to Enlarge QU50354 Synchro Sleeve is a genuine New Process Gear Replacement Part. Actuated by QU10929 Mode Fork, this part will rarely need replacement unless there is an underlying problem such as broken Shift Fork Pads that inhibit smooth shifting between 4x2 and 4x4 modes. QU50354 Synchronizer Sleeve fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks with NP241DHD transfer cases plus all 1994, 1995, 1996, and 1997 Dodge Ram 3500 4x4 trucks with NP241DHD Transfer Cases. Made in U.S.A.

Please refer to QU50354 page for more details and ordering information.
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Tools
     
QT2050 1994-1996 NP241DHD Transfer Case Small Bore Rear Output Bushing Remover and Installer for early Dodge NP241DHD Transfer Cases with 32 spline output shafts. Change the rear output bushing on your transfer case the easy way! 
     
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(continued from above) All gas V8 trucks with a manual transmissions and all automatic trucks regardless of their engine is a 23 spline input.  Whereas, all manual transmission trucks with a Cummins Diesel or Gas V10 engine will have a 29 spline input shaft. The NP241DHD has a 1-1/2" wide chain, a bearing supported planetary, and a SAE 6 Bolt PTO opening on the right side. Almost all 1994 to 1996 NP241DHD transfer cases, plus a few 1997 models have a two-piece tailshaft housing and a 1-3/8" diameter 32 spline output shaft. A stronger version of the NP241DHD is with a 1-5/8" diameter 31 spline output shaft, which was phased in starting with the late 1996 and early 1997 model year Ram of 2500 and 3500 Ram trucks. The upgraded NP241DHD transfer cases will be found in most 1997 trucks and all 1998-2002 models. These transfer cases have a one-piece tail housing and take a slip yoke that is about 14% larger in diameter than the previous slip yokes. The 1997 and earlier models have a mechanical speedometer output that drives an external electronic sender. Again, whereas, the 1998 to 2002 models do not have any provisions for a speedometer because the speedometer signal for these years is generated by the ABS sensor on the rear axle. If you are trying to swap parts between cases you will find some parts are interchangeable between the DLD and DHD models for a given year, but many are not. You also have to watch for variations within 1994-1997 model years as input shafts and the cut of the planetary teeth often changed within each assembly.