1994-2002 Dodge Ram NP241DLD Transfer Case Identification IDN-404

ID My 1994-2002 Dodge NP241DLD or NP241DHD Transfer Case IDN404
Dodge used New Process NP241DLD and NP241DHD Transfer Cases in 1994-2002 Ram Heavy-Duty 4x4 Trucks. Both the DLD and DHD are 2 speed with neutral, aluminum case, left drop, chain drive, manual shift transfer cases with a 2.72:1 planetary drive low range. They were manufactured by New Process Gear in Syracuse New York.

The NP241DLD (DLD=Dodge Light Duty) was the base transfer case for Ram 2500 models and 1994-1997 Ram 3500 trucks (Most Ram 3500 4x4s were built with the DHD). 
The New Process NP241DHD (DHD = Dodge Heavy Duty) Transfer Case was optional on 1994-1997 Ram 3500, 1997-2002 Ram 2500, and standard on 1998-2002 Ram 3500 models.

All 1994-2002 Dodge Ram NP241DLD/NP241DHD Transfer Cases were built with a round metal tag affixed to the center of the rear case half. These red and silver tags bear the legend New Process Gear Syracuse N.Y.. Stamped on the tag is the Model Number, Assembly Number, Serial Number/Build Date, and Low Range Ratio. Factory built NEW units ALWAYS have an assembly number that starts with 52 (ex: 52105024AB). Factory authorized Chrysler rebuilt cases usually have a replacement tag that replaces the 5 with an R (ex: R2105024AB). Cases rebuilt by the aftermarket, often have the original tag removed, or worse have a tag from a different application (the rear case halves are interchangeable between 1994-2002 DLD and DHD models, plus some GM units).

Ordering parts for an original unit or a Chrysler Reman unit based on the tag number is pretty simple as we know what parts are in or should be in the case. Cases rebuilt by aftermarket rebuilders will probably have some surprises due to the high level of part interchangeability for different years and also the likelihood that the rebuilder substituted at least some inferior quality components for original spec parts during the rebuild. If you know your rebuilt case was an exchange unit from an aftermarket rebuilder, we recommend you disassemble the case and ID the parts (especially the input bearing) before ordering parts. Tip: New Process did not paint transfer cases. If your transfer case is painted, chances are it was rebuilt by an aftermarket rebuilder.

PTO Cover:
If the tag is missing or unreadable, a quick way to ID if a case is a NP241DLD or NP241DHD is to look for a 6 bolt rectangular PTO Cover affixed to the right side of the front case half. The PTO cover is ONLY found on DHD models.

Rear Output Shafts:
1994-2002 NP241DLD:  32 spline x 1-3/8" (approximate) rear output shaft and a 2-piece bearing housing/extension
1994-1996.5 NP241DHD (Assy # begins with 5209):  32 spline x 1-3/8" (approximate) rear output shaft and a 2-piece bearing housing/extension
1996.5-2002 NP241DHD (Assy # begins with 5210): 1-Piece Tailshaft Housing and a 31 spline x 1-5/8" (approximate) diameter rear output shaft

Speedometer Drive:
1994-1997 Has Mechanical Speedometer Drive
1998-2002 No Speedometer Drive (speedo gets signal from Rear Axle ABS Sensor)

Input Shaft:
23 Spline, 5-3/64" Long: 1994-1995 RH Series Automatic, 1994-2001.5 Gas V8 with 5 Speed Manual Transmission
23 Spline, 4-5/16" Long: 1996-2002 with RE Series Automatic
29 Spline: 1994-2002 Cummins Diesel or Gas V10 and either 5 or 6 Speed Manual Transmission, 2001.5-2002 Gas V8 with 5 Speed

Also See:
IDN-400 NP241D Planetary Tooth Differences
IDN-401 NP231, NP233, NP241, NP242 Input Bearing Width Tech Help
IDN-402 Input Shaft High Range Clutch Teeth
IDN-403 NP231/NP241 Input Shaft Chart
XV-400 1998-2002 Dodge NP241DHD Input Shaft and Related Parts Exploded View
XV-401 1998-2002 Dodge NP241DLD Input Shaft and Related Parts Exploded View
XV-402 1994-1997 Dodge NP241DHD Input Shaft and Related Parts Exploded View
XV-403 1994-1997 Dodge NP241DLD Input Shaft and Related Parts Exploded View