NP261 to NP241swap

I swapped out an NP261HD transfer case from a 2005 Chevy Silverado 2500HD to an easier to find and cheaper NP241 out of an early 90's Chevy 2500. There are many different designs of both transfer cases but I will give a list of some of the major differences below. This is only for Chevy trucks, these 241 transfer cases were used in Chrysler products as well but I do not have any info on those.
Wiki entry for decoding New Process/New Venture Gear numbers
en.wikipedia.or...
NP261/NP261HD/NP261XHD - Manual Shift
NP263/NP263HD/NP263XHD - Electronic Shift
Input Shafts
NP241
THM400 - 32 Spline
4L80E - 32 Spline
Manual Trans - 32 Spline
700R4 - 27 Spline
4L60E - 27 Spline
From what I have read from 1994 up the planetary gears were cut differently on the 241 so swapping input shafts between the pre 94 and 94 on transfer cases may not be possible.
NP261/NP263
4L80E - 32 Spline
Manual Trans - 32 Spline
4L60E - 27 Spline
NP261XHD/NP263XHD
Allison Transmission - 29 Spline
4WD Switch
88-93 2 wire switch (non electronically controlled transmissions)
94-up 3 wire switch (electronically controlled transmissions)
I have read there may be some overlap between 94-96
Vehicle Speed Sensor
The speed sensors all work in the same manner and are 2 wire units. They may have different plugs and will have to be wired in directly but from what I have been able to find they all use the same 40 tooth tone wheel.
Output Shafts
There are yoke and flange style output shafts.
There is also a passengers side drop 241 transfer case
I don't have the year/model breakdowns for these differences but you should be able to find out with some google reasearch.
Amazon Store
www.amazon.com...

[@More350Power]

Looks like with the right parts you can make almost anything work together when you need to, good fix!

[@robertdavis6708]

I liked this video because you saved some gentleman a lot of money. Congratulations on your success.

[@leroygreen1877]

my 241c with an 80e shifts funny in low, one time on snow in low I was in overdrive at 20 mph and the shift were very quick. If I use low I keep the trans in first or second locked. I'm pretty sure pushed hard enough the ecu would force the 2 to 3 up shift.

[@kegtappereiu]

Thank You!!! There is so little info on the Np 261. All I could find info on was the 205 and the 241

[@marcowens-gq5sy]

The NP261 comes in 99-07 3/4ton very strong and durable transfer cases.

[@More350Power]

Errr, I meant looks like with any parts you can make anything work when you need it, good stuff !

[@codydunn242]

Pump rub got the transfer in my 03 and it is electric with auto 4x4, would rather have the floor shift and 5spd but don't think I'll do that till later.

[@KD0CAC]

I've got 01 GMC 2500HD with 4L80E , it has a NP263 , and was thinking the same thing , looking to see what I can exchange the NP263 for hard to find and cost too much when I do .

[@marcusjones3789]

Awesome thanks buddy im going to try it day

[@drpepr96]

Instead of that switch on the dash, why wouldnt you mount a momentary push button that gets pressed by the shifter when it's in 4 low. Kinda exactly like how your brake switch works, hell you could even use a brake switch.

[@heatherlynnbennett3514]

I have a 261 that is destroyed is the 243 the same or better I'm having someone replace the 261 he said he went to pick up the other transfer case and it is electric shift are there electric shift 261 I'm wondering if he's putting a 243 in it

[@bah53]

The electric shift version of a 261 would be a 263. The 241 and 261 are manual shift and the 243, 246 and 263 are electric shift. I don't know what it would take to go from manual to electric.

[@68chevelle496]

How did you end up connecting the floor shift linkage with the ball on the np261 to the bar on the 241c linkage

[@brendan747]

I converted the truck in my profile picture to 4wd, would you happen to be able to get the wiring diagram for the wires from the transfer case to the computer, and also the harness diagram from the front diff to the computer

[@dano4572]

isn't the 261 case stronger than the 241 case? the middle number says the strength of the case,,so bigger number,,stronger case?? ?????

[@williambowen2815]

Did you use a gasket on those 6 bolts between the NP241 and the transmission?

[@bah53]

+William Bowen yes

[@Isleepin516]

Awesome info..did the t case bolt right up?

[@kevinhornbuckle]

This video is very informative. Thank you. On the 241 is there a 4 Hi setting? Can you run in 4 Hi at highway speeds?

[@Isleepin516]

Yes there is

[@klc317]

Great work!!

[@bah53]

klc317 Thanks

[@jubyaz2832]

I did this swap and it wouldn't shift...mines was auto trac and put in a Manuel

[@cullen9017]

do you think you could do the same thing with an np261xhd out of a duramax?

[@elmichoacano4609]

cullen9017. I got a 261 transfercase on a 2000 silverado and it wont transfer power just quit working

[@RomneyGack]

What is your next vid?

[@discoveryman59]

MacGyver would be envious.

[@codydunn242]

You just put a half ton transfercase into a 3/4 ton truck.

[@HorsepowerGarageVideos]

That truck looks pretty beat up for a 2005.

[@bah53]

I don't know what my name is It's pretty beat up. It started out as a contractors truck, now its a farm truck so its been worked hard.