TK2522 Transfer Case Bearing, Seal, and Gasket Kit for 1998-1999 NP241DHD

Assembly Numbers: 52105026, 5210527, 52105028

For Master Overhaul Kit, See: TK2504

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Dan the Gear Man® Tech Notes:
TK2504 Master Overhaul Kit
Average Life
Oil Needs
Cracked Housing Causes
Replacing Chain
Contents of 1998-02 NP241DHD
Parts Included
Applications

Tech Note 1: TK2504 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 come close to the quality and completeness of our Master Overhaul Kits. If you want to do a first-class, long-lasting rebuild, the TK2504 Kits are the only way to go.

Tech Note 2: Average Life
Typically, the NP241DHD series transfer cases are usually the second longest lasting drivetrain component on a 1998-2002 Dodge Diesel truck (the Cummins is #1). Average life is in excess of 250,000 miles with recommended fluid changes.

Tech Note 3: Oil Needs
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 6.5 (1999) or 6.51 (2001) pints of Dexron II (1999) or Mopar ATF+4 (2001) 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 750 lb.-ft.

Tech Note 4: Cracked Housing 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 5: Replacing Chain
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: Contents of 1998-2002 NP241DHD
All 1998-2002 NP241DHD Transfer Cases will have a 31 slip yoke rear output with no speedometer drive, left side chain driven front output, front CV flange and manual shift engagement. All 1998-2002 NP241DHD transfer cases will also have a 6-gear planetary 2.72:1 ratio low range. 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. 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: Parts Included
TK10513 32 Spline Front Output Seal
TK10586 Extension Housing Gasket
2 QU10800 Vacuum Switch and Poppet Plug O-ring
QU10801 Front Output Seal
QU10802 Oil Pump O-ring
QU10824 Shift Shaft Seal
QU10825 Shift Shaft O-ring
QU10857 Input Seal
QU10879 Front Output Rear Needle Bearing
QU10896 OE Rear Seal
QU50114 Unitized Input Needle Bearing
QU50177 Oil Pump Seal
QU50201 Planetary Bearing
QU50207 Rear Output Ball Bearing
QU50874 Narrow Input Bearing
QU50875 Front Output Front Bearing

Applications:
Dodge NP241DHD, Auto, Cummins Diesel 5.9, 8.0 Liter with Narrow Input Bearing:
Ram 2500, Ram 3500 with NP241DHD Transfer Case Assembly Numbers- 52105026, 52105027, 52105028: 1998, 1999, 1999.5