The New Process NP241DHD (Dodge Heavy Duty) Transfer Case was optional on 1997 Ram 2500 and 1994-1997 Ram 3500 for most year and drivetrain combinations although most Ram 3500s were built with the NP241DHD.
All 1994-1997 Dodge Ram NP241DHD Transfer Cases were built with a round metal tag affixed to the center of the rear case half. These red and silver tags bear the legend New Process Gear Syracuse N.Y.. Stamped on the tag is the Model Number, Assembly Number, Serial Number/Build Date, and Low Range Ratio. Factory built NEW units ALWAYS have an assembly number that starts with 52 (ex: 52099036). Factory authorized Chrysler rebuilt cases usually have a replacement tag that replaces the 5 with an R (ex: R2099036). Cases rebuilt by the aftermarket, often have the original tag removed, or worse have a tag from a different application (the rear case halves are interchangeable between 1994-2002 DLD and DHD models, plus some GM units).
Ordering parts for an original unit or a Chrysler Reman unit based on the tag number is pretty simple as we know what parts are in or should be in the case. Cases rebuilt by aftermarket rebuilders will probably have some surprises due to the high level of part interchangeability for different years and also the likelihood that the rebuilder substituted at least some inferior quality components for original spec parts during the rebuild. If you know your rebuilt case was an exchange unit from an aftermarket rebuilder, we recommend you disassemble the case and ID the parts (especially the input bearing) before ordering parts. Tip: New Process did not paint transfer cases. If your transfer case is painted, chances are it was rebuilt by an aftermarket rebuilder.
If the tag is missing or unreadable, a quick way to ID if a case is a NP241DLD or NP241DHD is to look for a 6 bolt rectangular PTO Cover affixed to the right side of the front case half. The PTO cover is ONLY found on DHD models.
1994-1997 era Dodge NP241DHD transfer cases were built with two different rear output shaft types. Assemblies with 5209 as the first four digits of the assembly number have a 32 spline x 1-3/8" (approximate) rear output shaft and a 2-piece bearing housing/extension. Assemblies with 5210 as the first four digits of the assembly number have have a 1-Piece Tailshaft Housing and a 31 spline x 1-5/8" (approximate) diameter rear output shaft. The 32 spline models are typically 1994-1996.5 model year units and the heavier, 31 spline cases are in some late 1996 trucks plus all 1997 DHD equipped Ram 2500, Ram 3500.
