TK2523 Torque King® 1994-1996 NP241DHD Bearing, Seal, and Gasket Kit

TK2523 Torque King® Transfer Case Bearing, Seal, and Gasket Kit for all 1994-1996 Dodge NP241DHD transfer case units with 32 spline rear output shafts. Fits These Assembly Numbers: 52098505, 52098512, 52098534, 52098677, 52098678, 52099036, 52099037.

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Dan the Gear Man® Tech Notes:
Transfer Case Life
Lubricants/Sealants/Threadlockers
Damaged Housing Possible Causes
Chain and Sprockets
1994-1997 Transfer Case Specs
TK2523 Kit Contents
Applications

Tech Note 1: 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 2: 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 3: 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 4: 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 5: 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 6: TK2523 Kit Contents
TK10513 32 Spline Front Output Seal
QU10610 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
QU10857 Input Seal
QU10879 Front Output Rear Needle Bearing
QU40366 Front Output Seal
QU50114 Unitized Input Needle Bearing
QU50177 Oil Pump Seal
QU50201 Planetary Bearing
QU50873 Wide Input Bearing
2 QU50875 Front Output Front Bearing

Applications
Dodge:
Ram 2500 and Ram 3500 NP241DHD Transfer Case with These Assembly Numbers: 52098505, 52098512, 52098534, 52098677, 52098678, 52099036, 52099037: 1994, 1995, 1996