Specifications

P/N 716053
P/N 716054
P/N 716096
1995 & Newer
(tall & narrow)
Part number
needed:
716095 (5-1/8”)
Pre-1995
(short & wide)
Part number
needed:
716053 (5-1/8”) or
716054 (4-1/8”)
.935” ±
.630” ±
Note: Some XJ models with the NP240 series case are an exception to the above
year differences. Please specify if your case is a NP240 series out of an XJ model.
NP231 INPUT GEARS
94
1987 & newer jeeps - np series transfer case
1987 & NEwER JEEPS
(JEEP NP200 Series Transfer Cases):
The New Process transfer cases used in late model Jeeps are always a left-hand drop configuration and have the same circular
bolt pattern as the Dana 300. One of the differences between the Dana 300 and New Process transfer case is the rotation. The
stock rotation on the New Process transfer case depends on the year of the vehicle and the stock transmission used. The rotations
are approximately 13 or 23 degrees. Most of our adapter housings will have both sets of six adapter-to-transfer case mounting holes.
The illustration (right) shows both rotations.
The input splines on these transfer cases vary from 21 to 23 splines, and the transmission that is mated to these transfer
cases had either a long or flush output shaft length. It is crucial that you identify the correct
spline length and tooth count before ordering any adapters.
There are numerous styles of New Process transfer cases, and you must be very
careful in making your identification of such. The first units were the NP207s,
and they were used in the early model Cherokee Jeeps. The full size Jeep trucks
and Grand Wagoneers used the NP208. Jeep soon added the NP231 which replaced
the Model 207 in 1987. A Model NP242 was also added for the full time 4WD models.
SPLINES:
With all of the variations in model numbers, the only variation that we see concerning
transmission adaption is the size and tooth count of the transfer case input spline. As
mentioned in the second paragraph, the New Process transfer case has two basic spline
counts and each spline count has two different lengths. Both the NP207 and NP231 transfer
cases were available with these two different input splines. The input splines of the transfer
case can be changed if necessary, but the complete transfer case will need disassembly.
The easiest way that we have found to identify the proper transfer case input is by
identifying the stock transmission that Jeep used. The 21 and 23 spline output shafts
vary on different transmission models. The AX15 transmission is always 23 spline and
protrudes 1/2" beyond the face of the transmission. The Torqueflite and NV3550 are
normally a flush 23 spline. The AX4 & AX5 always have 21 splines and is flush with
the back of the transmission adapter until 1996; and then in 1997, the AX5 output shaft
was lengthened to a 1/2” stickout past the tailhousing adapter. The Peugeot
transmission is always 21 splines and protrudes 1/2" beyond the back of the
transmission adapter housing. We have seen the AW4 automatic transmission in
both a long 21 & 23 spline.
On the Transfer Case Selection Chart, we have listed the stock Jeep transmissions used with each transfer case. You can also
refer to the Stock Jeep Transmission & Bellhousing section for additional transmission identifications. If you have a 21 spline transfer
case, you will notice that some transmission applications are not available. On these applications and on high horsepower
applications, we recommend changing your input gear to a 23 spline. This will allow you to use the transmissions listed for the
23 spline applications and will also give you added strength.
P/N 716053A - New Process 231 T/C 23TH input 1987-94 (used for flush output shaft stickout on transmission)
P/N 716054A - New Process 231 T/C 23TH input 1987-94 (used for long output shaft stickout on transmission)
On Jeeps 1995 & newer, New Process used a different planetary assembly. The two part numbers listed above will not work with
this transfer case. To the best of our knowledge, this transfer case can be identified by one of three case model numbers:
52097-894, 52098-361, and 52098-540.
Another way to differentiate between these assemblies is illustrated by the
photo right. If you have one of these model transfer cases and wish to
change to a 23 spline input, the input gear required is AA P/N 716095.
The gears listed above will not work with the NP207 transfer case. If you
have a 1987 Jeep equipped with the NP207 21 spline input gear and wish
to add some strength to your drivetrain, you can purchase a new 23 spline
input gear (P/N 716096). This new gear was designed for transmissions
with a flush output shaft stickout. Transmissions having a .500” stickout
past the adapter housing may require the transmission output shaft to be
modified.