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My son has a 89 ford f150, 5 speed 4x4. His speedometer wasn't working and we checked the cable and the driven gear. All works fine. I took a mirror and managed to look inside the transfer case and the gear inside the case is shot. Looks like it is concaved and worn down. Do we need to pull the transfer case apart to replace this gear? When pulling the transfer case apart is there anything I need to watch for (such as springs or other items that might just "pop" out or fall off)? In all honesty I'm trying to determine if this is something that we can do or if I'm better off seeing if I can get an expert to do it. Any info is greatly appreciated.
you can get to it through the tailshaft if you really want to... I'd go with Conanski's suggestion and get a Haynes manual at your local part store. The transfer case is easy to pull... Just a few bolts to detach both drive shafts. Then take the bolts out that connect the t-case to the tranny. The spline shaft will hold the case up on it's own w/out the bolts in. then just slide the t-case back and off! i like to take the t-case off when i have to work on it... Even when it's something simple like the speedo gear. Honestly you might want to take a look to see why the speedo gear is shot... and you only have 2 more bolts for the front drive shaft and the tranny/t-case bolts and it's off!
PS: if you take the T-case off then get the new circular seal for when you put it back on. also you might want to check your U-joints and change your tranny and T-case fluid at this point if you haven't already...
Sometimes all you need to do is tighten the bolt that holds the tailshaft housing, if it is not tight the drive gear will just spin. Good Luck.. (or is it fixed now?)