TK2520 Bearing and Seal Kit for 1994-1995 NP241DLD Transfer Cases

Assembly Numbers: 52098503, 52098530, 52098675, 52098676, 52099035, 52099041

For Master Overhaul Kit, See: TK2501

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Dan the Gear Man® Tech Notes:
Kit Components
Master Overhaul Kits
Transfer Case Savers
Oil
Housings
Drive Chain
No PTO
Matching Parts
Applications

Tech Note 1: Kit Components
TK2520 Kit Includes:
Bearings: QU50114, QU10879, (2) QU50875, QU50873
O-Rings: (2) QU10800, QU10802, QU10825, QU10678
Seals: QU10610, QU40366, TK10513, QU10824, QU10857, QU50177

Tech Note 2: Master Overhaul Kit
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, the TK2501 Master Overhaul Kits are the only way to go.

Tech Note 3: Transfer Case Savers
Typically, the NP241 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. Other than just getting worn out, the only somewhat frequent failure area is the rear output shaft snap ring. It is not really all that common, but the snap ring has been known to fail, which allows the mainshaft to move forward. This will cause shift issues and almost always destroy the range fork. I personally believe most snap ring failures are related to overstretching the ring during installation, but you can eliminate this problem entirely by replacing the snap ring with one of our QK2069 Transfer Case Savers.

Tech Note 4: Oil
One way to kill your transfer case is to run it out of oil or with either wrong or dirty oil. My 1997 Dodge Shop Manual recommends 5.0 pints of Dexron II 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, reliability starts to really suffer when input torque exceeds 700 lb.-ft.

Tech Note 5: Housings
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: Drive Chain
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: No PTO
All 1994-1997 NP241DLD Transfer Cases will have a 32 slip yoke rear output with mechanical speedometer drive, left side chain driven front output, front CV flange and manual shift engagement. All 1994-1997 NP241DLD 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 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.

Tech Note 8: Matching Parts
QK2069 Transfer Case Saver
TK2520 Bearing and Seal Kit
QU10942 Vacuum Hose Harness
QU10929 Mode Fork
QU50078 Aluminum Range Fork
QU50144AM Cast Iron Range Fork
QK2006 Front Output Flange Kit
QU50153 6 Pinion Planetary Assembly
QU10923 Speedo Drive Gear
QU50355 Upper Chain Sprocket
QU50513 Lower Chain Sprocket
QU11166 NP241 Synchronizer Hub
QT2050 Rear Output Bushing Remover/Installer
Dodge & Ram Shop Manuals

Applications:
Dodge:
Ram 2500 4x4: 1994, 1995 with NP241DLD with these Assembly Numbers: 52098503, 52098530, 52098675, 52098676, 52099035, 52099041