How To Replace The Transfer Case In Your 2003 Dodge Ram 2500
If you have a 2003 Dodge Ram 2500, it’s not exactly a spring chicken. Chances are you have wracked up some miles along with the years, and it might be time to replace some key components. One thing that often needs a replacement for a workhorse of a truck like the Dodge Ram 2500 is the transfer case. You’ll find the steps to complete such a project right here.
What Do You Need for the Job?
Before you start removing bolts from your truck, it’s probably a good idea to do a little preparation. For starters, you need to make sure you get the correct transfer case for replacement. The 2003 Dodge Ram 2500 uses an NP271 transfer case. You can also check the part numbers on your transfer case and any replacement you are considering. If those part numbers match up, then you won’t have to worry about compatibility.
Additionally, the NP271 is not a light component for your truck. It weighs about 80 pounds, so you will want something to help you manage that weight. You can find more information on the specs of the NV271 transfer case here, https://reman-transmission.com/transfer-cases-code/NP271-NV271. A transmission jack can go a long way. On that same topic, a hydraulic jack and jack stands are worth a lot for this project.
Lastly, you might want a teardown manual to make sure you have torque specs for all of the bolts and nuts. The nuts that secure the transfer case itself only need to be snug, but some of the other things you might move to make room for the job will have different torque specifications.
Pull Out the Old Case
When your preparations are complete, you can work on removing the current transfer case. It’s always a good idea to disconnect the battery and secure the vehicle. You need to disconnect the drive shafts, which requires leaving the transmission in neutral. So if you don’t have a vehicle lift, make sure you chalk the tires and keep everything nice and secure.
With that done, the first real step in this process is draining the transfer case. You can pull the drain bolt and let all of the lubricating fluid out.
When it’s drained, you can start the removal process. The first thing you will want to remove is the rear driveshaft. When that is complete, you might find that the crossbar that holds the transmission in place is in your way. You can secure the transmission with a jack stand (use a 2X4 or something comparable to displace the pressure so you don’t bend or puncture the drain pan). Once that is done, you can remove the crossbar.
With that out of the way, you can disconnect the front driveshaft. From there, it’s just a matter of disconnecting the transfer case itself.
There is only one electrical connector for an NP271 on a 2003 Ram 2500. When it is safely disconnected, you can remove the nuts that secure the case to the extension housing. There is also a vent that needs to be pulled free.
With that, everything is disconnected, and you can pull the old transfer case away from the truck.
Prepare the New Transfer Case
Before you start installing your new transfer case, a few preparation steps can help you avoid frustration. It’s a good idea to compare the new case to the old case. You can double-check that everything lines up and matches in shape and size. NP271 transfer cases were used with a number of different vehicles, so you want to verify that the lags, nuts, and inputs all match.
If anything doesn’t match, you can pull components from the old transfer case to ensure that the new one will be successfully installed.
Install the New Case
Your preparations are now complete. The installation will simply be the reverse of removal. First, secure the lags and nuts that hold the transfer case to the extension housing. Attach the vent and the plug. Attach the driveshafts, and replace the transmission mount and/or crossbar if you removed them.
When everything is attached and secure, fill the transfer case with fluid. It uses regular ATF. Check thoroughly for leaks. If your work all passes inspection, you can fire up the truck and test your work.
