Complete reseal kit for the New Process NP241 transfer case in 1987-2001 Dodge Ram trucks - case gaskets, input, output and shift shaft seals plus O-rings.
A Dodge Ram with a wet front driveshaft yoke, fluid on the crossmember, or a transfer case that takes a quart every oil change needs a reseal before the low fluid takes out the chain and bearings. This kit has the seals for a New Process NP241 teardown: the case-half and adapter gaskets, the input seal, the front and rear output seals, the shift shaft seal and the small O-rings for the shift rail and plugs. It matches the contents of the common TSK-241 reseal kit.
The NP241 is a part-time chain-drive transfer case with an aluminum case and a planetary low range. Dodge's 1998 Ram service manual gives it a 2.72:1 low range with 2-high, 4-high and 4-low positions, worked by a floor shifter attached directly to the shift sector. An oil pump at the rear of the mainshaft feeds the chain, gears and bearings. The input seal keeps transmission fluid out of the case, the output seals ride on the companion flanges or yokes, and the shift shaft seal sits where the lever enters the case. Because the case holds only a few quarts, a slow leak drops the level enough to starve the pump.
Dodge's service diagnosis chart starts with the rest of the driveline: hubs, axles, driveshafts and tires can make noises blamed on the transfer case. Clean the case, drive a day, and look for the highest wet spot. If the case is noisy in every mode, check the level before anything else; the factory fix for that symptom is to drain and refill to the bottom of the fill hole and look for leaks. A fluid level that climbs points to the input seal, not a case leak.
This kit is listed for the NP241 in Dodge Ram trucks with the 5.2L and 5.9L V8 from 1987 to 2001, the 5.9L Cummins diesel from 1994 to 1996, and the 8.0L V10 from 1994 to 1996. By 1998 Dodge was building light-duty and heavy-duty versions (NV241LD and NV241HD), and the HD case has a PTO cover and a larger capacity. Read the identification tag on the rear case, which gives the model, assembly number and low range ratio, and match it before ordering, or send us the year and VIN. A Jeep Rubicon 241OR is a different case with a 4:1 low range and is not covered here.
Our NP241 reseal guide covers the in-truck output seal job step by step. This kit is seals and gaskets only; if the bearings are rough or the chain is stretched, replace those while the case is split.
| Fits | New Process NP241 transfer case |
| Applications | 1987-2001 Dodge Ram 5.2L/5.9L V8, 1994-1996 5.9L diesel, 1994-1996 8.0L V10 |
| Interchange | TSK-241 / TSK241 |
| Contents | Case and adapter gaskets, output and input seals, shift shaft seal, O-rings |
| Shipping weight | 15.2 oz |
The kit is listed for 1987-2001 Ram V8 trucks and 1994-1996 Cummins and V10 trucks. Later heavy-duty trucks used the NV241HD, which has a PTO cover and different capacity. Read the tag on the rear case and send us the model and assembly number, or your year and VIN, and we will confirm it before ordering.
Dodge's 1998 Ram service manual lists Mopar Dexron II or ATF Plus, filled to the bottom of the fill hole with the truck level. ATF Plus has been superseded by ATF+4. Check your owner's manual for your year and do not add friction modifiers or additives.
The 1998 manual gives about 2.7 L (5 pints) for the light-duty NV241LD and about 3.1 L (6.5 pints) for the NV241HD, with more on HD cases with a PTO. The fill level is the real answer: fill until fluid reaches the bottom edge of the fill hole.
Yes. The front and rear output seals can be done with the case in the truck by removing the driveshaft and companion flange or yoke. Use a new flange nut, since Dodge says the old one is not reusable. Case-half and input seal leaks need the case on the bench.
Match what came out of your unit. The 1998 manual seals the case halves and rear extension with a thin bead of Mopar Gasket Maker. Use the kit gaskets only where your case used gaskets, and keep any sealer bead thin.
