XV4000 Dan the Gear Man® Exploded View
1994-1996.5 NP241DHD 32 Spline Output Transfer Case
1994-1996.5 NP241DHD 32 Spline Output Transfer Case
Available Kits for 1994-1996 New Process NP241DHD
Torque King® Master Overhaul Kits
are absolutely the highest quality and most complete NP241DHD transfer case overhaul kits available for your 1994-1996 Dodge RAM 2500 or Dodge RAM 3500 4x4 bar none.
For Assemblies:
52098505 | 52098512
52098534 | 52098677
52098678 | 52099036
52099037
Use TK2507
For Assemblies:
52098153
Use TK2519
Torque King® Bearing and Seal Kits
include all the original equipment quality bearings, seals, and o-rings you need.
For Assemblies:
52098505 | 52098512
52098534 | 52098677
52098678 | 52099036
52099037
Use TK2523
For Assemblies:
52098153
Use TK2528
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XV4000
1994-1996.5 32 Spline Output NP241DHD
Transfer Case Exploded View Scene Index
1994-1996.5 NP241DHD Introduction >
User Guide >
XV448 Input Shaft and Planetary >
Input Shaft, Bearing, and Planetary Parts Selector >
XV449 Front Output Shaft >
XV450 Rear Output or Main Shaft >
XV451 Oil Pump and Pickup >
XV452 Shift Parts >
XV453 Front Case >
Front Case Note >
PS1000 PTO Bolts/Cover Selector >
XV454 Rear Case Parts >
Speedometer Driven Gears and Small Parts >
More Resources >
You May Also Need >
Kits >
Page 1 of 17
1994-1996.5 Dodge NP241DHD Introduction
The New Process NP241DHD (Dodge Heavy Duty) Transfer Case with a 32 spline rear output shaft and a 5209 Assembly Number prefix was Optional in 1994-1996.5 Ram 2500 4x4s and standard on the Ram 3500. There were numerous design changes in the NP241DHD during these years; making part(s) selection a bit tricky without the round transfer case build tag affixed to the rear case half.
NP241DHD Transfer Cases in gas V8 trucks with a manual transmissions and all automatic trucks regardless of their engine have a 23 spline input. Whereas, all manual transmission trucks with a Cummins Diesel or Gas V10 engine will have a 29 spline input shaft. Despite the many assembly variations, there are a few common characteristics shared by all 1994-1996.5 NP241DHD models. All these cases will have a slip yoke rear output, left drive chain front output, front CV flange and mechanical shift engagement. The cases will also have a 6-gear planetary 2.72:1 ratio low range. All 1994-1996.5 NP241DHD units have a transfer case mounted vacuum switch, which controls the front axle disconnect system. Also, mechanical speedometer output was used for these years.
Also, the NP241DHD has a 1-1/2" wide chain, a bearing supported planetary, and a SAE 6 Bolt PTO opening on the right side. 1994-1996.5 Transfer Cases had a 1-3/8" x 32 Spline Rear Output Shaft and a two piece rear output housing. The 32 spline output NP241DHD was replaced during the 1996 model with a stronger 31 spline output version.
Also, the NP241DHD has a 1-1/2" wide chain, a bearing supported planetary, and a SAE 6 Bolt PTO opening on the right side. 1994-1996.5 Transfer Cases had a 1-3/8" x 32 Spline Rear Output Shaft and a two piece rear output housing. The 32 spline output NP241DHD was replaced during the 1996 model with a stronger 31 spline output version.
Parts for 1996.5-1997 NP241DHD Transfer Cases with 5210 Assembly Number prefix and 1-5/8" diameter 31 spline output shaft are covered in my XV4001 Exploded View.
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