IDN-400 NP241D Transfer Case Input Shaft & Planet Gear Tooth Differences

IDN-400 1994-2002 Dodge Ram 2500, Ram 3500 NP241DLD, NP241DHD Transfer Case Input Shaft & Planet Gear Tooth Differences Many early production (1994-1995 and possibly some very early 1996) Ram 2500, Ram 3500 4x4 trucks with New Process NP241DLD and NP241DHD transfer cases have a wide cut planetary gear set. While the planetary gear tooth profile is visibly different from the 1994-2002 narrow tooth gears, the diameters of the 3 pieces (Input, Planetary, Annulus) are also slightly different. As you can see in Table 1 below, the gear diameters are around 0.020"-0.025" different. 

Ideally, the gearing from the two planetary types should not be mixed. However, due to a lack of new parts for the wide tooth planetary sets, there may be times when exceptions must be made. Realistically, the only part interchangeability is to use an input shaft from a 1994-2002 narrow planet application in a 1994-1996 wide tooth planetary. Table 2 below, shows the mix and match details. Many thousands of narrow tooth inputs have been used in wide tooth planetary units especially for transmission conversion applications. There have been few reported problems even though the gear tooth contact is not optimum.

Table 3 below, lists the front case half choices for NP241DHD Transfer Cases. Table 4 for NP241DLD models is under construction.

Also See:
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
IDN-404 ID My 1994-2002 Dodge NP241DLD or NP241DHD Transfer Case.
XV-400 1998-2002 Dodge NP241DHD Input Shaft and Related Parts
XV-401 1998-2002 Dodge NP241DLD Input Shaft and Related Parts
XV-402 1994-1997 Dodge NP241DHD Input Shaft and Related Parts
XV-403 1994-1997 Dodge NP241DLD Input Shaft and Related Parts