I have a 1987 W150 w/ a D44 manual lockout front axle. I was wondering if the backlash adjustment is the same as that era 9.25 with the adjuster inside the axle tube that you need a special hex insert tool to get to; and in turn thats how the carrier comes out. If so where can I get that special tool? If not should it pop out with a couple pry bars once everything is loose?

Backlash on Dana axles is handled by shims behind the bearings. This makes it a tight fit in most housings. Dana reccommends using a tool called a case spreader to remove the diff. In most cases you can get it out with a little prying once the axles are out and the bearing caps are off.

Thanks

You can also use the pinion to help get the carrier out. After you have removed the axles and carrier bearing caps, put a box end wrench on one of the ring gear bolt heads. Turn the pinion until the wrench is tight against the axle houseing. A few turns of the pinion and the carrier "should" walk right out.
For the final carrier bearing preload add about .003 shims on each side for final assembly.

I would suggest either buying or building a case spreader as you're going to want it to reinstall the carrier anyway. I've heard of people installing them without a spreader, but I haven't tried it and wouldn't even consider trying it after installing them with a spreader.

i would rather hit in a carrier with a dead blow hammer then overexpand a housing and crack it. it is not that hard to pound in a carrier with preload.

i would rather hit in a carrier with a dead blow hammer then overexpand a housing and crack it. it is not that hard to pound in a carrier with preload.

How far are you trying to expand it? They don't need to go very far...

I've heard of people cracking or stretching housings but I honestly don't know how it would happen unless someone were pretty careless. Maybe I've just been lucky.