yo Eric,
yw.
Drain all fluid through drain plug; see more below;
Here is the 1345 Rebuild
http://www.broncohq.com/pdf/80-96/chassis/1345transfercase.pdf
1345 was used in 250's and 350's but for some reason this doc does not show Bronco, unless I missed it.
See Fig 2 for drain and fill plug locations on rear cover
See Page 16-86-7 for refill; replace drain plug;
Minimal torque; tighten to 6-14 ft lbs
add 6 pints of Ford auto tran fluid meeting spec shown through fill plug hole
Should fill to around level of fill plug holse, so try and park on sevel durface.
Minimal torque again; tighten fill plug to 15-25 ft lbs
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And from my old Chilton;
Borg-Warner 1345 � Dexron� II ATF - some peeps use synthetics
Type: Chain-driven, aluminum
Low-range ratio: 2.72:1
Lubricant: ATF
Length: (in.): 17.25
Width (in.): 23.0
Height: (in.): 12.0
Used by: Some 1980-to-88 full-size Fords. Holds six pints of Dextron II ATF. This unit can be towed extended distances
because of its built-in pump that channels oil to all necessary bearings.
Our Bro here in BroncoZone
Justshootme84 (RIP BRO) wrote here;
The B-W 13-45 can be found on 83-87 Broncos, although the NewProcess 208 is more common. Like the 208, the 13-45 is chain-drive and has an aluminum case. You want to keep the skid plate under the rig, as the case can easily be damaged if you drive over a large rock or tree. WHile the chain can stretch over time, most cases should give 200K miles of service or more. The number one cause of failure is lack of fluid killing the pump. And if your t-case has the weird plugs with the 7/16" square, inset holes, you can easily swap them out with some hex-head brass plugs from a hardware or auto parts store. It's easier to check the fluid that way on a regular basis (2-4x/year). For more info on t-cases, check out www.truckpulls.com JSM84
http://broncozone.com/topic/9531-borg-warner/