TK2521 Torque King 1996-1997 NP241DHD Bearing, Seal & Gasket Kit

TK2521 Torque King® NP241DHD Bearing, Seal, and Gasket Kit for 1996-1997 Dodge New Process NP241DHD transfer cases with 31 spline rear output shafts.

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:
Kit Components
TK2503 Master Overhaul Kit
Longevity
Common Causes of Failures
Additional Common Causes of Failures
Drive Chain
NP241DHD Transfer Cases
Matching Parts
Applications

Tech Note 1: Kit Components
TK2521 Includes:
TK10513 32 Spline Seal
TK10586 Extension Housing Gasket
QU10678 Speedo O-Ring
(2) QU10800 O-Ring
QU10802 Oil Pump O-Ring
QU10824 Shift Shaft Seal
QU10825 Shift Shaft O-Ring
QU10857 Input Seal
QU10879 Needle Bearing
QU10896 OE Rear Seal
QU40366 Front Output Seal
QU50114 Input Needle Bearing
QU50177 Oil Pump Seal
QU50201 Planetary Bearing
QU50207 Rear Output Ball Bearing
QU50874 Narrow Input Bearing
QU50875 Output Bearing

Tech Note 2: TK2503 Master Overhaul Kit
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: Longevity
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: Commons Causes of Failures
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: Additional Common Causes of Failures
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: NP241DHD Transfer Cases
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: Matching Parts
Matching Parts for TK2521 Bearing, Seal, and Gasket Kit:
TK2503 Master Overhaul Kit
QU90025 Tailshaft Bushing
QU10512 Front Output Flange Nut
QU10587 Access Plug
QU10572 Planet Thrust Washer
QU10589 Shift Link Grommet
QU10673 Oil Pump Connector Hose
QU10674 Oil Pump Screen
QU10814 Planetary Snap Ring
QU10815 Rear Output Bearing Snap Ring
QU10816 Rear Output Shaft Snap Ring
QU10817 Speedo Gear and Rear Output Snap Ring
QU10818 Front Output Rear Snap Ring
QU10872 Synchro Hub Snap Ring
QU10872 Speedo Gear Snap Ring
QU10873 Speedo Gear Snap Ring
QU10874 Front Output Front Snap Ring
QU10893 Input Shaft Snap Ring
QU50080 Retainer Ring
QU10820 Strut Tension Spring
QU10821 Shift Synchro Strut
QU50000 Drive Chain
S24200 6ml Blue Threadlocker
QU90006 3.35oz Ultra-Black RTV Sealant

Applications
Dodge New Process NP241DHD transfer cases with 31 spline rear output shafts: 1996, 1997