I am wondering if I can remove the back cover of my Borg-Warner 13-45 transfer case ('87 F-250) to change speedometer drive gear. If I do, will anything have to be aligned? I would like to attempt this on the truck if possible. Thank you in advance for your help.

 

You need to remove the rear output shaft yoke first with a 32mm socket (preferably with an impact wrench...it's on there tough). The socket needs to have a thin wall to fit inside the yoke to get a grip on the nut. Most impact sockets are too thick. I needed to use a socket out of a cheapo socket set. Then drain the case, remove the 4x4 light cable and the speedo cable. Remove the many bolts holding it all together and then crack the case open. It was hard to crack mine open...took a couple of pry bars to get it open and I had the whole thing on a work bench. Might be hard if it's still attached to the tranny. When the case is split, pull out the rear output shaft, pry the rear seal off...you will need a new one (about $10), pull out the speedo gear, replace, and then put in new seal. Good time to check the bearing too. Also, check the magnet at the bottom of the case for metal filings and check the oil filter pickup to see if clogged. Make sure hose going to oil pump from pickup is intact. My hose was gone because the oil pump bracket broke and it was spiining free on the shaft which caused hose to break and disintegrate and thus caused my needle bearing to chew themselves up into a zillion microscopic pieces. Long story. If you have questions, e-mail me at shimonmor(No Email Addresses In Posts!).