I have an 03 Ram 3500 5.9 cummins, with nv4500 5speed, 273d elec trasfercase.
I have been looking for information on what transfer case i can replace the 273d with, i have gone thru 2 in 2yrs because of the chains eating the inside out.
I can not find any info on swapping the 273d out for
bw44-46
Anyone have any insight whether it'll direct bolt to the nv4500, or what I'd have to change, adapt.
or any insight on another tc I could look into that'll bolt up and hold up.

 

Why are yours failing? They usually last a long time. Drive on pavement when engaged in 4x4? It get low on fluid?

 

I don't know why, i got the truck and could hear the chain grinding the inside wall so I replaced tc with a reman, bout a year I could hear the chain on the new one grinding inside wall and ended up blowing apart down interstate. I dont use 4x4 unless I need it and I replaced front drive shaft when I replaced tc. I do tow often though, which I thought might be y the tc wore out but idk. I check fluid often cuz I tow a lot. Anyway, tc is too expensive to be replacing every year so I was trying to find one that would be stronger that would bolt up, otherwise I'll just put another 273d in

 

The 273 is theoretically pretty stout..... Any warranty left on the latest tc?

 

I would replace it with an NV271.

 

I'd have your driveline checked out, phased correctly? CV joint rebuilt? Were your axles replaced at some point and have non matching ratios? Mounts in good shape? pinion angles extreme from a lift? quality rebuilder?

I know its not the answer to your question but it would be nice to figure out why yours are failing. Replacing with a heavier unit just prolongs the inevitable and /or destroys something else, 1 transfer case per year is definitely the extreme and not normal, I know these have a habit of blowing up on the interstate at 75mph, but not that often.

 

Its been just over the 12mth warranty so I'm stuck with the cost.

 

Truck is pretty stock aside from intake and 33s. I replaced ujoints on rear drives haft when I swapped tc, and at first just replaced the cv joint in the front drive shaft before I swapped tc cuz pre owner said that's what was wrong with it, but ended up being the tc, so when I swapped tc I replaced the whole front drive shaft cuz the co I bought tc from said it had to be replaced with tc in order to have warranty on tc. Which expired so doesn't help anyway.
The one thing that stayed was the motor transfered from old tc to new tc, possible it was bad, or i just got a bad reman.
I rebuilt the nv4500 with new clutch bout half way thru year and replaced trans mount at that time.
if the 273 is known to be a strong tc then I'll just put one back in, any recommendations on who to go thru for one without a core since mine went poof.

 

I would find an NP271 manual shift transfer case from a junkyard with the lever, linkage, and boot so you can get rid of the electric shift junk.

 

Another option is get a tcase from a place that has longer warranties. Powertrain products has 5 year warranties with an optional 7. Zumbrota has 2 years. Don't know if they require new front driveshafts, and professional install... you'll have to call. Not a cheap repair. I like not having the floor cluttered with that shifter, but electric shift does add complexity.

Or you could go with a jyard unit, and rebuild it yourself. I don't think they're that complicated, basically two gears and a chain.

You must keep those tcases topped off with oil.... they get a little low, and the chain will stretch and you've got issues again.