I found this video which illustrates rhe replacement of the 2003 front output housing (with the CDL nipple) with the 2004 front output housing:

 

Thanks.

Ran down to Houston yesterday to get a transfer case but drilled a dry hole - all the case were listed as '04 but were '03.

Back to square one.

 

Do not try to lift the t-case. It's too heavy to manipulate accurately and you need to be careful when you slide it onto the transmission output spline. You need a transmission jack for sure.
I swapped mine without a lift. Just put the truck on some ramps. If you use a lift, you'll have to work out how to get the tranny jack up high enough to use it, plus you need to be able to get in and out of the cab to do stuff inside as well as underneath.

 

I always remove the rear round plate, and then the gear set for more wiggle room personally.

 

what's the rear round plate?

 

I know I'm reviving an old post, but I can't find relevant information on the topic of NV225 transfer cases. I just acquired a 2002 P38. The tranny was run without fluid and burnt up the wiring harness. While removing the T-case, we took the case apart to inspect the chain. It can move up and down about 3/4". It seems about border line needing to replace. I was looking for a new chain and found the STC3238 chain and also the HV-083 chain. The HV-083 is listed for the 03-05 NV225. Based on the conversation above, it seems like there are differences that may not affect the drive chain. The HV-083 is ~$80 while the STC3238 is ~$650. Does anyone know if the HV-083 will fit on the older 98-02 NV225?

 

You'll likely get more traction on rangerovers.net or in the P38 forum on here. All D2s have the LT230 so folks here may not have as much info to share on the borg warner case found in the RRs