2. GM New Process 208/241

NP208/241 TRANSFER CASE DETAIL IDENTIFICATION:

The New Process 208 is a chain-driven transfer case.  This is a cast aluminum transfer case.  Compared to the NP203 and NP205, the light-weight cast aluminum housing of this transfer case is easier to handle.  This transfer case is a good gear box with a low ratio of 2.61:1.  The weakest part of this transfer case is that the shifter fork wears easily, causing shifting problems.  This transfer case was used in production vehicles manufactured from GM, Dodge, and Ford.  Identifying the GM version is done easiest by the round identification tag affixed to the case.  This transfer case has a right hand drop configuration, is synchronized shifted, and has a rear slip yoke.  The GM NP208s have either a female 27 tooth input spline (originally coupled to a 700R transmission)(* see footnote), or a female 32 spline input (originally coupled to a SM465 or TH400 transmissions).

The New Process 241 is also a chain-driven transfer case.  This is a cast aluminum transfer case.  Compared to the NP203 and NP205, the light-weight cast aluminum housing of this transfer case is easier to handle.  This transfer case is a good gear box with a low ratio of 2.71:1.  Since this is the newest design of the New Process transfer case models, the weak links of this transfer case are few and far between.  GM uses this transfer case in both right hand and left hand drop configurations.  Even with these two configurations, the adapters we manufacture work the same since the bolt pattern on this transfer case is symmetrical.  This transfer case is used in production vehicles manufactured from GM, Dodge, and Ford.  Identifying the GM version is done easiest by the round identification tag affixed to the case.  This transfer case is normally a right hand drop on vehicles with a solid front axle, and a left hand drop on vehicles with I.F.S.  The GM NP241s have either a female 27 tooth input spline (originally coupled to a 700R or 4L60E  transmission), or a female 32 spline input (originally coupled to a SM465, TH400, or 4L80E transmission).

Both of these transfer cases utilizes the same conversion adapters.  One of the only areas of concern with these transfer cases is actually the crossmember support used by GM.  Vehicles 1981-1984, used a crossmember with a drop; the stock adapter having a long foot to couple to this crossmember support.  The 1985 & newer vehicles came with a crossmember that was tucked up tightly to the frame rails, thus requiring a short foot on the adapter housing.  There are only a couple of our adapters that retain the stock adapter housing in which this will be of no concern.  The adapter kits that supply a new adapter housing are all designed for the later crossmember support.  If you are converting a 1981-84 vehicle, you may be required to fabricate a crossmember spacer or purchase a later model GM crossmember.

NP208 transfer cases were normally right drop and NP241 were normally left drop transfer cases.

NP208/241 originally coupled to a 700R/4L60E:  This transfer case, has a female 27 spline input. 1982-85 700R has the long foot on the casting. 1986 & new casting were short foot castings.

NP208/241 originally coupled to a SM465/TH400/4L80E:  This transfer case has a female 32 spline input. SM465's up to 1984 have the long foot on the casting and are 8.25" long.  

*Note:  There were a few TH350 transmissions used in 1980 till 1982 GM vehicles.  The stock adapter length is approximately 5" on these applications.

 

The following photos are examples of the different O.E. castings with the different crossmember height differences as well as some of the length differences.

NP208-SM465 long foot 1          NP208 NP241-SM465 short foot            NP208-SM465 long foot              NP208-700R long foot              700R & TH400 to NP208 NP241 1            700R & TH400 to NP208 NP241              700R NP208 NP241 short-long foot GM

 

Tech Vault

Our Technical Data Knowledge Base contains information............ Learn More ›

 

Testimonials

See what others are saying about Advance Adapters!! Click Here!

 

Contact Us

Call us today at 800.350.2223 or email us directly here!