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My new to me 94 f350 5 speed diesel powerstroke crew cab long box has a bad 1356 transfer case (huge pieces of metal rolling around inside)
I've got the option on a late 80's f250 diesel 5 speed transfer case (in great shape).
Aside from counting the splines, and checking that the tail is the same length, do i need to consider anything else?
Do i just plug the speedo cable hole?
If you're breaking 1356 cases you don't want to go with anything weaker. The case on that '80 is probably an NP208. This will bolt up just fine with minor mods for shifter fitment, but a 208 is a good deal weaker thana 1356, and a 1356 isn't exactly real strong. Even a 1345 isn't that strong. My advice is to stick with a 1356 unless you're really in a pinch and need 4x4 now. Only good thing about 208 cases is you can find 'em all day for $20-$50, and they are light enough to change by yourself in under an hour.
Probably, as long as they are both fixed yoke or slip yoke cases. Throw the new case in, worst case is the shifter may be a bit different if it's from a different body style.