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

TK2503, TK2507, TK2519 1994-1997 Dodge NP241DHD Transfer Case Torque King® Master Overhaul Kits are absolutely the highest quality and most complete NP241DHD transfer case overhaul kits available for your 1994-1997 Dodge Ram 2500, Ram 3500 4x4 truck bar none. Kit includes Genuine New Process and/or U.S.A. made ball bearings,  Morse® OEM drive chain, Torrington straight roller bearings, OEM quality Input/Output Seals and o-rings, plus all these Genuine OEM Small Parts: planetary thrust washers, all snap rings, shift fork pads, tailshaft housing bushing, oil pump hose, oil pump screen oil pump seal, front output spline seal, and front output lock nut. Also includes RTV sealant, and threadlocker. Each kit is custom tailored for your specific NP241DHD transfer case from original equipment parts lists.
Bearings
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 have the wide QU50873 (15/16") or narrow QU50874 (5/8") width input bearing. Also, there are two choices for the rear output bearing depending upon if you have the large 31 spline or small 32 spline rear output shaft. Link to Our Dodge Web Page Index
QU50873 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. Approximate bearing width is 15/16". Note: QU50873 replaces QU50176

Link to QU50873 product page or click on the button to the right to see this item in our Web Store

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.
QU50874 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. QU50874 is the current original equipment bearing supplied by New Venture and it will provide many years of reliable service. Includes snap ring is pre-installed in bearing groove. Approximate bearing width is 5/8". Note: QU50874 replaces QU50158

Link to QU50874 product page or click on the button to the right to see the item in our Web Store

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 QU50873 shown above is the correct bearing for your input shaft.

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).

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) Order QU50083 Sealing Plug below.

Please refer to QD10000 page for more details and ordering information.

QU50875 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. QU50875 replaces QU50157

Link to QU50875 product page or click on the button to the right to see this item in our Web Store

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.

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

QU50502 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 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.

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.

Please refer to QU50201 page for more details and ordering information.

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.

Please refer to QU10879 page for more details and ordering information.

Bushings
Early production 1994-1997 NP241DHD Transfer Cases had small, 1-3/8" 32 spline rear output shafts, 2 piece tailshaft housings and use QU10130 Bushing. All the 1994 and 1995 models have the 32 spline shaft. 1996 is the transition year in which the 32 spline units were phased out and replaced by models with one piece tailhousings, 1-5/8" 31 spline rear output shafts and use QU90025 Bushing. By 1997, the 32 spline units were no longer used except perhaps for some early model year V8 gas engine trucks. By now, many 1994-1997 era trucks have had the transfer case replaced, so verify what Bushing you need before ordering. Link to Our Dodge Web Page Index
QU10130 Small Bore Genuine New Process Rear Output Bushing for 1994 to 1997 NP241DHD transfer cases with two piece tailshaft housings. Your rear output shaft will be about 1-3/8" in diameter, have 32 splines, and the driveshaft slip yoke will be approximately 1-7/8" in diameter.

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

QU90025 Large Bore New Process NP241DHD Rear Output Bushing fits those 1996 and 1997 NP241DHD Transfer Cases with one piece tailshaft housings. Your output shaft will be about 1-5/8" in diameter, have 31 splines, and the driveshaft slip yoke will be approximately 2-3/16" in diameter.

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

Case Halves
Typically, the aluminum main case castings on NP241DHD transfer cases will last the life of the vehicle even though they do not appear to be near as rugged as the NP205 cast iron cases used on 1993 and older 4x4s. However, there are a number of situations that can wreck one or both case halves. Since Dodge Ram 2500 and 3500 4x4s have coil spring front suspension with light gauge trailing arms, any accident involving a front end impact is likely to push the front axle and driveshaft backwards which can break one or both case castings. Other common killers are loose chains wearing through the case, whacking the case on a rock when off-roading, and operating the unit with low oil. Link to Our Dodge Web Page Index
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 to 1997 Dodge Ram 2500 and Ram 3500 4x4 trucks with NP241DHD transfer cases.
Case Parts
QU10189 New Process Transfer Case Rear Extension Assembly is a genuine NPG part that includes factory installed QU10130 Rear Driveshaft Support Bushing and QU10610 Rear Output Seal. QU10189 is specific to 1994-2001.5 Dodge NP241 series transfer cases, but it fits a host of other New Process aluminum chain drive transfer cases with 32 spline output shafts including 2001.5-2002 Dodge NP241DLD models. Limited Supply!
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.
QU11054 1994-1997 NP241DHD Rear Extension Housing for 1994-1997 Dodge New Process NP241DHD Transfer Cases with QU10968 32 spline output shafts

See more applications & detail on our large text QU11054 individual page.

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.

QU70005 6 Bolt PTO or Inspection Cover New takeout covers from new units we have disassembled for parts. For all NP241DHD Transfer Cases.
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.

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:

Link to Our Dodge Web Page Index
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.

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.
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. Dodge 1996-1997 NP241DHD Transfer Case assembly numbers 52105092 and 52105314.
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.
Miscellaneous
Replacing damaged or worn small parts is often the difference between a first class, long-term repair and a short lived nightmare. In this section are the small parts and accessory items that do not neatly fit under our other parts headings. Link to Our Dodge Web Page Index
QU10942 Main Vacuum Hose Harness for 1994-1997 Dodge Front Axle Disconnect. Goes from engine line to transfer case switch & down to the frame cross member.
QU11044 Transfer Case Plug

Please refer to QU11044 page for more details and ordering information.

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.
QU11141 Rear Bearing Retainer or Extension Housing Bolt with factory applied Threadlocker
QK2069 Transfer Case Saver Kit for New Process 241DHD Transfer Cases with 32 SPLINE rear output shafts (These transfer cases have rear driveshaft slip yokes that are approximetly 1-7/8" in diameter). 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.

Will not work on late 1996 or 1997 NP241DHD transfer cases with with 31 spline rear output shafts and a 1 piece tailshaft housing. This includes MOST 1997 241DHDs' and any 1996 241DHD model with the 2.2" diameter output yoke!*


Oil Pumps and Oil Pump Pickup Parts
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.


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.
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.

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 1996-1997 31 Spline Dodge NP241DHD Transfer Cases is a genuine, original equipment New Process Gear replacement part. Pre-assembled, 31 spline pump for large diameter output shaft. includes QU50177 Oil Pump Seal. QU10936 Transfer Case Oil Pump fits 1996-1997 NP241DHD Transfer Case with 31 Spline, large diameter Rear Output Shafts. Order QU10802 O-ring separately.
QU50423 Oil Pump for 1994-1997 32 Spline Dodge NP241DHD Transfer Cases is a genuine, original equipment New Process Gear replacement part. Pre-assembled, 38 spline pump for small diameter output shaft. includes QU50177 Oil Pump Seal. QU50423 Transfer Case Oil Pump fits 1994-1997 NP241DHD Transfer Case with 32 Spline, small diameter Rear Output Shafts. Order QU10802 O-ring separately. NOTE: Your output shaft has 32 splines for the slip yoke and 38 splines for the oil pump. QU50423 drive hub has has a 38 splines.
O-Rings
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.

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.

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.

Output Flanges and Yokes
QK2006 Front Output Flange Kit for fits all 1994, 1995, 1996, and 1997 Dodge Ram 2500 4x4 trucks plus al 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. No Longer Available. Use QU40700
QU50043 Front Output CV Flange Yoke is a genuine original equipment replacement part for all 1994 to 1997 HP241DHD Transfer Cases.
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).
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). (There 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.
Planetary Assemblies
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.
Poppet Parts
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.

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.

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.

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 for more details and ordering information.

Seals
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.

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.


QU50514 Front Output Seal for all 1994-1997 Dodge NP241 series Transfer Cases. QU50514 is a genuine NPG original equipment Seal with triple seal lip construction.
NP205 32 Spline Yoke and Shaft Seal 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.

QU10896 OE Rear Output Oil Seal for 1996-2002 Dodge transfer cases with 1 piece rear.
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.

Link to Our Dodge Web Page Index
QU50144 Cast Iron Range Fork Genuine New Process original equipment Range Fork fits all 1994-1997 Dodge NP241DHD Transfer Cases and NP241DLD Transfer Cases.

Please refer to QU50144 page for more details and ordering information.


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.

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.

Please refer to QU50150 page for more details and ordering information

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.
Shift Parts
QU10942 Main Vacuum Hose Harness for 1994-1997 Dodge Front Axle Disconnect. Goes from engine line to transfer case switch & down to the frame cross member.
  QU10628 Mode Shift Fork Spring is a genuine new process part
  QU10629 Mode Fork Spring Plate (Spring Cup) is a genuine new process part that fits between the QU10628 mode shift fork spring & rear case half.
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
.

QU10164 Mode Fork or Range Fork Shift Pad fits the tips of all QU10929 1994-1997 Dodge 241DHD series Mode Forks and Range Forks. These genuine, original equipment New Process gear pads are tough and durable. Requires 2 per Fork. QU10164 Range Fork or Mode 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.

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.


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*


Slingers
     
QU10646 Slinger for all 1994-1997 Dodge NP241DLD and NP241DHD Transfer Cases.

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

     
Small Parts
     
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.


QU10512 Front Output Nut 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. 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.

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.

QU50761 Aftermarket Input Shaft to Planetary Thrust Washer
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
QU11140 Long Case Bolt for New Process Transfer Cases. A QU11140 Bolt fits through each of the two hollow front case half to rear case half alignment pins.

Link to our QU11140 Catalog Web Page
QU11141 Rear Bearing Retainer or Extension Housing Bolt with factory applied Threadlocker
QU11138 Transfer Case to Case and Rear Extension Housing to Rear Bearing Retainer Bolt with factory applied Threadlocker. Most 241 series Transfer Cases will use eight of these genuine New Process Gear original equipment QU11138 Bolts to attach the front and rear case halves to each other and four to secure your rear extension housing to the rear bearing support.
QU11039 Planetary Lock or Thrust Plate for New Process Chain Drive Transfer Cases is a genuine original equipment part that fits most New Process and New Venture chain drive transfer cases with low range. The Tanged Lock Plate is the heavy 1/8" thick cast iron thrust plate that is located between the outer plastic Planetary Thrust Washer and the Planetary Snap Ring.
QU50191 Chip Magnet for all 1994-1997 Dodge New Process NP241DHD Transfer Cases.
     
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. Link to Our Dodge Web Page Index
  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  
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.
Speedometer Parts
All 1994 to 1997 Dodge NP241DHD transfer cases have a speedometer drive gear, but there are two different gears depending upon if the transfer case has a 31 or 32 spline rear output shaft. An 1-3/8" diameter 32 spline output shaft was used on most 1994-1996 NP241DHD transfer cases. A stronger, 1-5/8" diameter 31 spline output shaft was phased in during the 1996 model year. Link to Our Dodge Web Page Index
QU10923 Speedometer Drive Gear is a genuine original equipment New Process plastic gear for 1994-1996 Dodge NP241DHD transfer cases with 32 Spline Rear Output shafts.
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.
QU10873 Speedometer Retaining Snap Ring for 1994-1996 Dodge NP241DHD 32 Spline (Small Shaft) Transfer Cases.
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. Link to Our Dodge Web Page Index
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.
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.
Synchronizer Parts
     
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.

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.

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 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 QU10819 page for more details and ordering information.

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.

QU11166 1994-1997 Dodge NP241DHD Synchronizer Hub is a genuine New Process Replacement Part.
Tools
NP241DHD Transfer Cases can be rebuilt with a minimum of special tools. One exception is replacing the thinwall rear output bushing which is pressed in an aluminum housing. Many rear extension housings and new bushings have been wrecked by folks trying to do the job with makeshift tools. Our Bushing Installers makes the job quick and easy. Link to Our Dodge Web Page Index
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 QU10130 rear output bushing on your transfer case the safe and easy way!
QT2044 1996-1997 Rear Output Bushing Remover and Installer is a low cost, CNC machined steel tool made to remove and install the QU90025 NP241DHD Rear Output Bushings from 1996-1997 NP241DHD models with 31 spline rear output shafts and one piece tailshaft housings when doing off vehicle gearbox service.
(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 perhaps few a 1997 models might 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.