Transfer case questions
The dodge heavy duty 241 has a 29 spline input, to bolt it up where a 231 was, you have swap out the input shaft for a 23 spline. I thought all 2nd gen dodge cummins came with the dhd 241 and a previous owner had an issue, found a 241 light duty, and swapped in a 29 spline input shaft. But after digging around, it looks like from '94 to '98 in the 2500's, it was possible to get a cummins with a light duty nv4500 and light duty 241. That's what the 2500's came standard with and the heavy duty nv4500 and heavy duty 241 were an option. And I couldn't find anything that said choosing the cummins automatically upgraded to the heavy duty trans and transfer case until '99. I would be getting a build sheet to see how it actually came from the factory, and go from there.
Champion
Joined: Apr 2011
Posts: 3,574
Likes: 0
From: Harrisburg,PA
I have pretty much become an expert at changing the transfer case in my truck.. Here is the steps I follow:
1. Remove Driveshaft
2. Unplug all connections and remove linkage
3. Find the right size wrench to remove the nuts holding the t-case to the trans and cut that little guy in half.
4. Remove all the nuts and just wiggle that bugger out of there.
I am now able to remove the transfer case and put it back in within 2 hours. Any questions just ask away.
1. Remove Driveshaft
2. Unplug all connections and remove linkage
3. Find the right size wrench to remove the nuts holding the t-case to the trans and cut that little guy in half.
4. Remove all the nuts and just wiggle that bugger out of there.
I am now able to remove the transfer case and put it back in within 2 hours. Any questions just ask away.
Veteran
Joined: Dec 2010
Posts: 492
Likes: 1
From: Brownsburg, IN
Interesting. I also noticed while poking around on rock auto that they list some DHD 241's with 23 spline inputs... so I guess there are all kinds of variations of each type of t-case. Seems excessive, but these were the days of 'order what you want.' Not as much as the 60's and 70's, but obviously more then today.
The 23 spline input DHD 241 came out of an auto. All DHD 241's behind a manual trans should be 29 spline input, as long someone didn't swap input shafts to a 23 spline and bolt in to a light duty nv4500.
Thread Starter
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Registered User
Joined: Dec 2011
Posts: 7
Likes: 0
From: Central Oregon
Ok, so we pulled the old case and set it next to the new to us case. The only difference is the output shafts. our old busted up case is 29 splines, the new one is 23 (if I remember correct). Ours is out of a manual trans with a cummins, the replacement is reportedly out of a v8 360 with manual trans. Both are 1994 trucks.
How does one go about swapping these shafts? Or is it not possible? Please let me know if you have any answers.
I have pix but have no idea how to post them.
Thanks again
Greg
How does one go about swapping these shafts? Or is it not possible? Please let me know if you have any answers.
I have pix but have no idea how to post them.
Thanks again
Greg
Record Breaker
Joined: Mar 2009
Posts: 1,814
Likes: 0
From: Memphis, TN
Anytime, i was really confused when i put in with the shifter in what was 2wd and i put in reverse and im in 4lo. I got a little excityed till i realized what happened lol.
Veteran
Joined: Dec 2010
Posts: 492
Likes: 1
From: Brownsburg, IN
Ok, so we pulled the old case and set it next to the new to us case. The only difference is the output shafts. our old busted up case is 29 splines, the new one is 23 (if I remember correct). Ours is out of a manual trans with a cummins, the replacement is reportedly out of a v8 360 with manual trans. Both are 1994 trucks.
How does one go about swapping these shafts? Or is it not possible? Please let me know if you have any answers.
I have pix but have no idea how to post them.
Thanks again
Greg
How does one go about swapping these shafts? Or is it not possible? Please let me know if you have any answers.
I have pix but have no idea how to post them.
Thanks again
Greg
The output shafts on the transfer case should be 32 spline (both transfer cases), do you mean the input shaft from one case to the other is different? If so, yes it's possible to switch shafts. The down side is there are four possible input shafts depending on bearing diameter and planetary gear cut.
Registered User
Joined: Oct 2017
Posts: 1
Likes: 0
241 Dld transfer case
Ok thanks for all the info I've read so far already got just one question So my transfer case went out going down the hwy in 2wd I have the 241 DLD now l found one allot cheaper only difference is my I.D number starts with 5209 and the one I'm looking at's I.D number starts with 5210 are the splines and everything a match, will it bolt in or if and what will i have to modify every thing else seems to be the same
