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Transfer Case Parts for Dodge

Dodge used the very strong, cast iron,  New Process NP205 two speed, gear drive, part time transfer cases in various models from 1969 to 1993. From  late 1974 to 1988, the NP205 was only offered in 1 ton trucks. From 1989-1993, the 205 was used in all Cummins Diesel W250 models and all W350 trucks. 

All 1974-1979 Ramchargers, 1974½-1979 W100/150, and W200/250 trucks were equipped with the combination gear drive/chain drive, full time,  New Process two speed NP203 transfer case as were some W350 models.  The 203 is rather unique in that the cast iron, low range unit was a actually a separate gear drive box bolted to the front of the cast iron chain drive case. The inter-axle differential was located behind the chain case inside an aluminum housing. 203's have a 1.96-1 low range.  The early NP203 models had a wide, 3/8" pitch chain that has a tendency to stretch and jump the drive sprockets.  Late model cases use a narrow 1/2" pitch chain that is much stronger. These later cases are quite reliable but not very fuel efficient.  The NP203 was discontinued after the 1979 model year.  A number of companies offered part-time conversion kits for the 203 to help boost fuel economy, however, converted 203's almost always suffer major lubrication related failures.  As an interesting sidelight, the NP203 range box is now one of the most sought after used part on the market.  A number of companies offer conversions to adapt the range box to more modern transfer cases for double low range capabilities.

From 1980 to 1987 Dodge used the two speed, NP208, chain drive, aluminum transfer case in all Ramchargers, W150 and W250 trucks.  While not a particularly robust design, the 208 generally gives good service unless abused or poorly maintained.  The 208 was the first New Process production transfer case to use a planetary gear low range.  The low range ratio is 2.72:1.  Early units from 1980 to 1982 were not synchronized.  Late 1982 to 1987 208's in Dodge trucks are synchronized for 4 wheel drive.

From 1988 to 1997 The NP231 and NV231 light duty, chain drive transfer cases were installed in Dakotas and some light 1/2 ton trucks. 

Dodge W150 and W250 trucks (except Cummins Diesel models) from late 1987 to 1993 have the two speed, NP241, chain drive aluminum transfer case.  All 1994-2002 Dodge 2500 and 3500, 4x4's are equipped with NV241 transfer cases.  Dodge 241's have a planetary low range ratio of 2.72:1. There were numerous design changes in the 241 during its production life making parts selection a bit tricky without the transfer case build tag. Starting in 1994, the stock 1500 and 2500 transfer case was the NV241DLD (Dodge Light Duty).  Optional on the 2500 and standard on the 3500 was the NV241DHD (Dodge Heavy Duty).

The NP271 manual shift and NP273 electric shift, chain drive transfer cases are found in 2500 and 3500 models effective for the 2003 model year.

See Our What's New Web Page

29 Spline Input Shaft Kit

32 Spine
Front Output Shaft Kit

QU50084 Rear Output Shaft

To Order, Go To Our NP205 Transfer Case Page

QU50084 NP205 Rear Output Shaft 

QU10528 89-93
29 Spline Coupler Sleeve

Coupler Sleeves are used with direct mount NP205 applications to couple the male transmission output shaft to the male NP205 input shaft.  Couplers are grooved in the center for a pre-installed snap ring which keeps the coupler centered on the two shafts.  For 1989-1993 Cummins Diesel trucks with 5 speed transmissions order our QU10528 29 spline coupler. All other direct-mount Dodge applications including 1989-1993 Cummins trucks with automatic transmissions use our 23 spline Coupler Sleeve. Made in U.S.A.

QU10528 89-93 29 Spline Coupler Sleeve Very Limited Supply.  $179.99
QU10855 75-93 23 Spline Coupler $179.99 Very Limited Supply.

QK2004
Front Output Flange Kit

Front output flange Kits mate to Saginaw CV and Spicer 1330CV Series, flange mount CV shafts on most Dodge full size trucks with 32 spline front output shafts. Kits include output flange with slinger, output seal, spline seal, nut, & Threadlocker. QK2004 also includes front bearing retainer gasket. Made in U.S.A.

QK2004 NP205 1975 to 1993 32 spline shaft $189.95
QK2006 NP208, NP241D, NP241DLD and NP241DHD 1980-1997 $175 Select Year: 1994-1996 1997 Select Engine: Gas V8 Gas V10 Cummins Diesel Select Transfer Case Model: 241DLD 241DHD
QK2037 Transfer Case Front Output Flange Kit for all 1998-2002  Dodge with New Venture NP241DLD and NP241DHD Transfer Cases in Ram Full Size Trucks. $139.97

Torque King® NP205
Master Overhaul Kit

THE ONLY KITS ON THE MARKET THAT INCLUDE  IDLER SHAFT SHIMS AND ALL SMALL PARTS!

Torque King® Master NP205 Overhaul Kit is the highest quality and most complete NP205 overhaul kit available for your rugged Dodge 205 transfer case bar none.  Kit includes American made ball bearings, Timken tapered roller bearings, Torrington straight roller bearings, genuine New Process precision thickness gaskets (critically important for bearing clearances), 4 rubber case access hole plugs, thrust washers, thrust washer pins, lock rings, detent springs, detent balls, roll pins, front output shaft nut,  idler shaft shims, National and Chicago Rawhide Seals, spline seals, RTV sealant, and threadlocker.  Kits include special double rear output seal set. Nearly all components Made in U.S.A., but some pieces are imported.
 

TK2000 OH Kit 1989-93 Diesel 5 speed $450
TK2011 1980-93 All EXCEPT Diesel 5 speed $450

Torque King®
Typical NV241DHD
Master Overhaul Kit

Torque King® Master Overhaul Kits are the best quality and most complete transfer case rebuild kits you can buy bar none.

Torque King™ Master NP241 Overhaul Kit is the absolutely highest quality and most complete NP241 overhaul kit available for your 241DLD or 241DHD transfer case bar none. Kit includes American made ball bearings (1 bearing imported),  Torrington straight roller bearings, planetary thrust washers,  Morse® drive chain, snap rings, o-rings, shift fork pads, main housing to tail housing shim gasket (late models), tailshaft housing bushing, oil pump hose, oil pump screen, National and/or Chicago Rawhide Seals, front output slinger (late model only), spline seals, RTV sealant,  and  threadlocker.  Each kit is custom tailored for specific NP241 transfer cases from original equipment parts lists.   Made in U.S.A. except Timken, Morse, National, and CR components may be made at other corporate locations worldwide.

TK2043 Master Kit for 52098675 $569.95
TK2046 Master Kit for 52098151 $569.95
TK2500 Master Kit for 52105024 $549.95
TK2501 Master Kit for 52098530 $549.95
TK2502 Master Kit for 52098503, 52098679 $599.95
TK2503 Master Kit for NP241DHD, 52105314  $599.95
TK2504 Master Kit for 52105027 $599.95

Many other kits available, we just haven't had time to add them!

Morse Brand Drive Chain

Transfer Case Mounted
Vacuum Switch

Vacuum Switch. Front Axle shift problems on 1994-2002 Dodge 4x4 trucks with vacuum controlled Central Axle Disconnect (CAD) are often caused by a defective transfer case vacuum switch.  Replace yours today with this genuine, American made, New Venture switch.  Fits all 1500, 2500, and 3500 trucks with vacuum axle disconnect systems. Made in U.S.A.

Transfer Case Saver Kit

Transfer Case Saver for all New Process 231 and 241Transfer Cases with the 2 piece tailshaft that uses 4 bolts to attach the extension housing to the tailshaft housing. Replaces the failure prone factory snap ring that holds the rear output shaft against the rear output bearing. Easy to install, patented design part includes two precision machined rings that bolt together, two bolts, threadlocker, & RTV sealant. Made in U.S.A. Will not work on cases with either the 3 bolt rear extension piece or models with 1 piece tailshaft housing.

QU50137 Transfer Case Saver Kit $49.97

QU50078
NP241 Range Fork

QU50144
First Design Range Fork

Shift Forks are genuine New Process/New Venture components for maximum durability and precise fit. Shift fork tip wear is fairly common in 205 and 241 transfer cases.  Most 205 transfer cases will need one or both forks after 150,000 miles or so due to normal wear.  241 forks that need replacement are often the victim of low/improper lubrication, broken snap rings, or bearing wear.  Early 241 Range Forks have replaceable fork pads;  late ones have molded, non-replaceable pads.  Made in U.S.A.

NP205 Shift Forks:
For pricing and to order 205 Forks go to our NP205 web page

NP241/NVG241 Range Forks are one of the most common hard parts requiring replacement in NP241 series transfer cases.  Over the years, New Process used several different range forks making it a bit more difficult to pre-order a fork prior to transfer case disassembly unless the transfer case tag number or year is positively known.

QU50078 NP241 Range Fork, 1997-02 $74.97
QU50144 NP241 Range Fork 1994-96 $159.97
QU10929 NP241 Mode Fork $154.95
QU10929AM NP241 Mode Fork (no pads), aftermarket $119.95   If you need pads, order 2-QU10164 and 1-QU10574 below.

Hard to Find Small Parts and Gaskets for your NP205 Transfer Case are in stock! Do a professional quality overhaul and replace those worn, critically important small parts. We have both Small Parts Kits and individual small parts including shims, lock rings, thrust washers, pins, springs, and about everything else you need to restore your 205! Go to our NP205 web page for pricing and to order.