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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, fixed rear output yoke, NP241, chain drive aluminum transfer case.  All 1994-2002 Dodge 2500 and 3500, 4x4's are equipped with NV241 transfer cases and slip yoke type rear output shaft.  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 2500 transfer case was the NV241DLD (Dodge Light Duty).  Optional on the 2500 and standard on the 3500 was the NV241DHD (Dodge Heavy Duty).  1999-2002 Ram 2500 and Ram 3500 4x4 trucks with the High-Output Cummins Diesel NV5600 6 speed transmission use the NV241DHD. 1994 to 2001 Ram 1500 models can have either a NP231, NP231HD, or NP241 transfer case depending upon the year, engine, and transmission combination.

The NP271 manual shift and NP273 electric shift, chain drive transfer cases are found in Ram 2500 and 3500 models effective for the 2003 model year.  These transfer cases feature larger rear output shafts to handle the ever-increasing power of Dodge factory engines.

The redesigned 2003 Ram 1500 debuted with a re-worked NV241D transfer case that is not interchangeable with prior models.

See Our What's New Web Page

29 Spline Input Shaft Kit

32 Spline
Front Output Shaft Kit

To See and Order NP205 Input and Output Shafts, Go To Our NP205 Transfer Case Page

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.	See Our New Process NP205 Web Page
QU10855 75-93 23 Spline Coupler Sold Out.	See Our New Process NP205 Web Page

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 1975to 1993 32 spline shaft	See Our New Process NP205 Web Page
QK2006 NP208, NP241D, NP241DLD and NP241DHD Please refer our New Dodge 1994-1997 NP241DLD or our New Dodge 1994-1997 NP241DHD pages.
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.	Please refer to our New Dodge 1998-2002 NP241DLD or our New Dodge 1998-2002 NP241DHD pages.

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 See Our New Process NP205 Web Page
TK2011 1980-93 All EXCEPT Diesel 5 speed $450

Torque King® Typical 1998-2002 NV241DHD Master Overhaul Kit 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 U.S.A.  made ball bearings (Rear output bearing on 1998-up 241DHD is imported),  Torrington straight roller bearings, planetary thrust washers,  Morse® drive chain, all 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, Original Equipment Quality Seals, front output slinger (late model only), spline seal, Front Output Nut, RTV sealant,  and  threadlocker.  Each kit is custom tailored for specific NP241 transfer cases from original equipment parts lists.   Mostly Made in U.S.A., some components imported.

Please refer to our New Dodge NP241DLD/DHD pages. Dodge 1994-1997 NP241DLD or Dodge 1994-1997 NP241DHD or Dodge 1998-2002 NP241DLD or Dodge 1998-2002 NP241DHD

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. Limited Supply.

Transfer Case Saver Kit

Transfer Case Saver for all New Process 231 and 241 Transfer 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 transfer cases with either the 3 bolt rear extension piece or any models with the 1 piece tailshaft housing. This includes ALL 1998-2002 241DHDs', MOST 1997 241DHDs' and any 1994-1996 241DHD model with the 2.2" diameter output yoke!

QK2069 Transfer Case Saver Kit Sold Out

Please refer to our New Dodge 1994-1997 NP241HDH page

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.