TK2503 1996-1997 Master NP241DHD Overhaul Kit

TK2503 Torque King Master NP241DHD Overhaul Kit for 1996-1997 Dodge New Process NP241DHD transfer cases with 31 spline rear output shafts. Torque King® Master Overhaul Kits are absolutely the highest quality and most complete NP241DHD transfer case overhaul kits available for your Dodge Ram 2500, Ram 3500 4x4 truck bar none. Kit includes Genuine New Process and/or U.S.A. made ball bearings, genuine OEM Morse® 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. Mostly Made in U.S.A. Some components imported.

Fits Assembly Numbers: 52105091, 52105092, 52105093, 52105314, 52105315, 52105513.

Need More Info? Use the handy Links below to access over 40 years of Dan's product and vehicle specific Tech Notes to easily get the information you need for your vehicle's repair, maintenance, or upgrade project!

Dan the Gear Man® Tech Notes:
Other Assembly Numbers
NP241 Upgrade Parts?
Transfer Case Life
Lubricants/Sealants/Threadlockers
Damaged Housing Possible Causes
Chain and Sprockets
1994-1997 Transfer Case Specs
Kit Contents
Applications

Tech Note 1: Other Assembly Numbers
TK2507 1994-1996 Dodge Ram 2500, Ram 3500 with these Assembly Numbers: 52098505, 52098512, 52098534, 52098677, 52098678, 52099036
TK2519 1994-1996 Dodge Ram 2500, Ram 3500 with this Assembly Number: 52098153

Tech Note 2: NP241 Upgrade Parts?
There are not any real "upgrade" parts for the NP241DHD series Transfer Cases. It is a pretty good transfer case for all gas and stock or mildly upgraded Cummins Diesel Dodge trucks when correctly assembled using original equipment quality parts. I rebuilt an awful lot of these things before I retired and I can tell you that I never saw any aftermarket rebuild kits that even comes close to the quality and completeness of our Master Overhaul Kits. If you want to do a first-class, long-lasting rebuild, these Kits are the only way to go.

Tech Note 3: Transfer Case Life
Typically, the NP241DHD series transfer cases are usually the second longest lasting drivetrain component on a 1994-1997 Dodge Diesel truck (the Cummins is #1). Average life is in excess of 250,000 miles with recommended fluid changes.

Tech Note 4: Lubricants/Sealants/Threadlockers
One way to kill your transfer case is to run it out of oil or with either wrong or dirty oil. My 1997 Dodge Factory Shop Manuals recommend 6.5 pints of Dexron II in the stock NP241DHD Or 9.0 pints in one with a PTO. I always use the synthetic version of the most current Dexron formula. The transfer case fluid should be changed every 36,000 miles to meet the Dodge maintenance schedule. Check your Dodge Ram Truck owners manual for the specific lubrication recommendations for your year and model. Excessive horsepower is another way to murder your Transfer Case. From what I have seen, NP241DHD reliability starts to really suffer when input torque exceeds 700 lb.-ft. with a 32 spline rear output and 750 lb.-ft. with a 31 spline rear output.

Tech Note 5: Damaged Housing Possible Causes
Cracked or broken housings are usually a result of:
Accident Damage: A good whack on the front axle will push the axle and driveshaft backwards.
High Centered: Off-Roading or sliding into a ditch without a skid plate.
Loose Mounting Nuts: Make sure the six mounting nuts are tight.
Stretched Chain: Not real common, but a loose chain will wear through the bottom of the case.
Run Out of Oil. If the bearings seize, your Transfer Case is toast.

Tech Note 6: Chain and Sprockets
Contrary to popular belief, the Drive Chain can not cause a clunk or contribute to "slack" in the drive train in 4x2 mode. The chain is only under power in 4x4 mode. You should always replace the chain when doing major transfer case service, plus you should inspect the sprockets for wear on the teeth. If you can feel teeth wear with your fingernail REPLACE BOTH the SPROCKETS and CHAIN!

Tech Note 7: 1994-1997 Transfer Case Specs
All 1994-1997 NP241DHD 5209 series Transfer Cases will have a 32 slip yoke rear output. All 1996-1997 NP241DHD 5210 series Transfer Cases will have a 31 slip yoke rear output. Both versions have a speedometer drive, left drive chain driven front output, front CV flange and manual shift engagement. All 1994-1997 NP241DHD transfer 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. The NP241DHD uses a 1-1/2" wide drive chain and it has provisions to mount a Power Take Off (PTO). The NP241DHD was optional for Ram 2500 trucks and stock on Ram 3500 4x4s.

Tech Note 8: TK2503 Kit Contents
TK2503 Kit Include: 
QU90025 Tailshaft Bushing
QU10512 Front Output Flange Nut
TK10586 Extension Housing Gasket
QU10587 Access Plug
4 QU10164 Shift Fork and Range Fork Tip Pads
2 QU10572 Planet Thrust Washer
QU10574 Mode Fork Pad
QU10875 Range Fork Shift Pad
2 QU10589 Shift Linkage Grommet
QU10673 Oil Pump Connector Hose
QU10674 Oil Pump Screen
TK10513 32 Spline Front Output Seal
QU40366 Front Output Seal
QU10857 Input Seal
QU50171 Rear Output Seal
QU10678 Speedometer O-ring
2 QU10800 Vacuum Switch and Poppet Plug O-ring
QU10802 Oil Pump O-ring
QU10824 Shift Shaft Seal
QU10825 Shift Shaft O-ring
QU10814 Planetary Snap Ring
QU10815 Rear Output Bearing Snap Ring
4 QU10817 Speedometer Gear and Rear Output Snap Ring
QU10818 Front Output Rear Snap Ring
QU10872 Synchro Hub Snap Ring
QU10874 Front Output Front Snap Ring
QU10893 0.094" Input Shaft Snap Ring
QU50080 Retainer Ring
2 QU10820 Strut Tension Spring
3 QU10821 Sift Synchro Strut
QU10879 Front Output Rear Needle Bearing
QU50114 Unitized Input Needle Bearing
QU50201 Planetary Bearing
QU50207 Rear Output Ball Bearing
QU50874 Narrow Input Bearing
QU50875 Front Output Front Bearing
QU50000 OEM Morse® Drive Chain
S24200 6ml Blue Threadlocker
QU90006 3.35oz. Ultra-Black RTV

Tech Note 9: Applications
1996, 1997 Dodge Ram 2500 and 3500 with NP241DHD Transfer Cases with Assembly Numbers: 52105091, 52105092, 52105093, 52105314, 52105315, 52105513