that's strange....i have a 86 f150 xlt 302/aod 4x4, and i have the borg warner case. Maybe ford just stuck whatever they had laying around in the trucks? lol

 

This is a 1345:


From my shop manuals, it's listed apps are Bronco and F250/350.

The 1356 was not factory installed until 87, it should not be found under an 80-86, unless it has been swapped.
The 1345 was fixed yoke only, while the 1356 which is the standard across the line transfer case 88+(I have seen a few 87 F150's with np208's) was available both fixed and slip, manual and electric shift.

The 208 was available in fixed and slip yoke forms, I have seen both styles in the same year, same engine/trans/body configuration trucks, so I don't really know what made the decision on what truck got which style.

 

The sterling 10.25 early type with short pinion splines and shorter yolk was put in F250's and F350's from 1985-1992. I have the early type, and it is developing the pinion shaft "wobble" that they fixed in the second generation 10.25. It had a longer pinion shaft, and longer yolk. It was used 1993-1998. In 1999 the 10.25 was replaced by the 10.50, which has a bigger ring gear, but unfortunately smaller pinion bearings. If you want even more gory details and/or knowledge on how to fix/upgrade your sterling axle, look here:

Ford 10.25 & 10.50-Inch Axle Tips - Four Wheeler Magazine

I re-checked all of my vin #'s, and the paper title, door sticker, windshield stamped plate and frame stamp all match. The door sticker says it was manufactured in Canada in February 1986. So I guess There has been no funny business there. The sterling axle is probably the correct one, but also probably not the original one. The door sticker has an axle code of "C5" which would be a limited slip with 4.10's. Now, either the axle has been replaced with a non-LS, or the clutches are so shot that it is now behaving like an open carrier. Don't know which.

The Front axel is a little puzzling. The Dana Spicer Bill of Materials number stamped on the axel tube is 610255-2, which identifies it as this:
610255 FORD 60 FRONT 1986-88 F-350 MONOBEAM DRW
...according to this web resource:

Dana/Spicer Bill Of Material Numbers

However, I remember reading that 1985-1991 D 60's had kingpins, and 1992 and later were ball joint types. All this tells me is that you can't believe everything you read on the internet! Another detail is the Dana BOM code above says it's for DRW, mine is not a dually! It is a SRW.... unless the DRW rear axle was swapped out for an SRW (see above) which is a possibility because the bed does not match the front half of the truck. So maybe it used to be DRW??? The rim studs up front are not for DRW rims though, don't know if this can be changed easily or not.

OK, I am waaaay off topic, sorry!

 

F834, the link you supplied is saying something else that I am finding somewhat contradicting. I have always heard that all Ford T cases regardless of which one are interchangable with all Ford trannys. The bolt pattern is supposedly the same regardless of what tranny T case combo out there. However, in the link you provided on pg 1 it is saying that the 1354 has a 32 spline count and all others have a 31 spline count. If this is really the case then what I have been told is false.

 

OUCH! I'm sure glad you pointed this out... the chart on the bottom shows that the BW 1345's came with EITHER 31 OR 32 splines depending on the year of application!!! The information I have found says that BW T18's and T19's in the 1980-1987 range were ALL 31 spline output shafts, so if my BW 1345 for the T19 is the 31 spline type then I probably can't use it with a ZF 5 speed (came mated to BW 1356's) if it has the 32 splines....

I'm not seeing where it says the 1356 has 32 splines, but the BW 1345's that have 32 splines came in 1988-1991 F series... 1988 being the same year they started using ZF's! Kind of looks to me like up to 1987 they were all 31 spline, then things got complicated. Look at the chart, 31, 32, 34 and 24 spline inputs depending on the brand and year!

Good catch, I think you might have saved me a whale of a headache over 1 spline! I'll check into this a bit more, but obviously they are not all interchangeable...

 

The difference in splines is on the output, not the input, all Ford inputs are 31 spline, a 1345, 205, 208, heck, even a 203 will bolt on a ZF. The 31 vs 32 output is slip vs fixed, fixed yoke is 32 spline, same as a NP205, and slip is 31, the same as the input, if you remove the extension housing on a 1356, you can slide another ford fullsize case on the output shaft no problem, making a cheap, but long doubler.
I find it strange for a listing to show a '45 as 31 spline though, I don't believe a slip yoke one exists.