TK2516 1999.5-2002 NP241DLD Master Overhaul Kit

TK2516 1999.5-2002 Dodge NP241DLD Transfer Case Torque King® Master Overhaul Kit with Wide Input Bearing is absolutely the highest quality and most complete NP241DLD transfer case overhaul kit available for your 1999.5-2002 Dodge Ram 2500 4x4 truck, bar none. This Kit includes the Wide Input Bearing. Kit includes Genuine New Process and/or USA Made ball bearings, genuine OEM Morse® Drive Chain, Torrington straight roller bearings, Input/Output Seals and o-rings, plus all these Genuine OEM Small Parts: planetary thrust washers, all snap rings, shift fork pads, main housing to tail housing shim gasket, tailshaft housing bushing, oil pump hose, oil pump screen, oil pump seal, front output slinger, spline seal, and front output shaft lock nut. Also includes RTV sealant, and threadlocker. Each kit is custom tailored for your specific NP241DLD transfer case from original equipment parts lists. Mostly USA Made, some components imported.

This Torque King® Master Overhaul Kit is our premium choice, most complete overhaul kit available, custom assembled with the highest quality parts here in Montana specifically for the 1999.5-2002 Dodge NP241DLD Transfer Cases. There are no knockoff parts in our Torque King® Kits! Rebuild your transfer case with confidence with our top quality parts! These are the parts we used when rebuilding transfer cases because our customers expect the best!

See TK2517 for Torque King® Master Overhaul Kit if you have the Narrow Input Bearing! Refer to your Transfer Case Assembly Number.

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:
Quality
Average Life
Oil
Causes of damaged Housing
Clunk
Stock Components
TK2516 Components
Alternate Kit
Applications

Tech Note 1: Quality
There are not any real "upgrade" parts for the NP241DLD 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 2: Average Life
Typically, NP241DLD series transfer cases are usually the second longest lasting drivetrain component on a 1999.5-2002 Dodge Diesel truck (the Cummins Transmission is #1). Average life is in excess of 250,000 miles with recommended fluid changes.

Tech Note 3: Oil
One way to kill your transfer case is to run it out of oil or with either wrong or dirty oil. My 1999 and 2001 Dodge Shop Manuals recommend 5 (1999) or 4.61 (2001) pints of Dexron II (1999) or Mopar ATF+4 (2001) in the NP241DLD. 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, NP241DLD reliability starts to really suffer when input torque exceeds 700 lb.-ft.

Tech Note 4: Causes of damaged Housing
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 5: Clunk
Contrary to popular belief, the Drive Chain cannot 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 6: Stock Components
All 1998-2002 NP241DLD Transfer Cases will have a 32 slip yoke rear output without a speedometer drive, left side chain driven front output, front CV flange and manual shift engagement. All 1998-2002 NP241DLD transfer cases will also have a 6-gear planetary 2.72:1 ratio low range. The NP241DLD uses a 1-1/4" wide drive chain and does not have a provision to mount a Power Take Off (PTO). The NP241DLD was only used on Ram 2500 trucks. 1998-2002.5 trucks with vacuum controlled Central Axle Disconnect have a transfer case mounted vacuum switch, which controls the front axle disconnect system. 2002.5 trucks without CAD will have a shift indicator switch. All models are synchronized for 4x4 mode engagement except assemblies ending with the letters AD.

Tech Note 7: TK2516 Components
QU10130 Tailshaft Bushing
QU10512 Front Output Flange Nut
TK10586 Extension Housing Gasket
QU10639 Wear Sleeve
QU10673 Oil Pump Connector Hose
2 QU10164 Shift Fork Tip Pad
2 QU10572 Planet Thrust Washer
QU10574 Mode Fork Pad
2 QU10589 Shift Linkage Grommet
QU10674 Oil Pump Screen
TK10513 32 Spline Front Output Seal
QU10610 Rear Output Seal
QU10801 Front Output Seal
QU10857 Input Seal
QU50177 Oil Pump Seal
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
QU10816 Rear Output Shaft 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
2 QU10820 Strut Tension Spring
3 QU10821 Shift Synchro Strut
QU10879 Front Output Rear Needle Bearing
QU50114 Unitized Input Needle Bearing
QU50873 Wide Input Bearing
2 QU50875 Front Output Front and Rear Output Bearing
QU50071 Drive Chain
S24200 6ml Blue Threadlocker
QU90006 3.35oz. Ultra-Black RTV

Tech Note 8: Alternate Kit
TK2526 Torque King® Bearing, Seal, and Gasket Kit with Wide Input Bearing

Applications:
Dodge New Process, New Venture NP241DLD with Wide Input Bearing:
Assembly Numbers: 52105023AB, 52105023AC, 52105023AD, 52105024AB, 52105024AC, 52105024AD, 52105025AB, 52105025AC, 52105025AD: 1999.5, 2000, 2001, 2002