: How to remove a broken dana 300 rear output shaft??


Aggro
05-07-2002, 03:28 PM
Yeah it's a newby question, and I'm a newby to dana 300's. It ain't like my dana 20, I'll tell ya that much!!! I have the rear output housing off. I have the input bearing retainer off, but the broken shaft won't come out. What am I doing wrong?

Jeepskickass
05-07-2002, 05:58 PM
The shaft is pressed into the gear it's riding in. You'll need to remove the input shaft, then press the output shaft out. If I remember correctly, I had to pull the intermediate shaft in order to get it out. Pretty much the whole case has to come apart to get the new shaft in, so you might as well tear it all down now.

Keith
05-07-2002, 10:07 PM
Brian, the front assy should come out as a whole unit after you pull the allen screws. There will be some needle bearings between the front and rear sections, sometimes they are caged. The fork clutch should stay on the fork. Once you have the rear bearing retainer and speedo goodies off, the only thing left in the input/rear output section should be the large gear, a shim, a tapered roller bearing and the shaft. If the shaft is busted, guess you dont have to worry about beating on it. Hang the input section off the side of a sturdy bench, and beat the living crap out of the shaft. Should pop the pressed bearing off with several hard wacks, and the shaft should fall out the input side of the case. To put the bearing back on, just use a piece of pipe, I thin about 1.5", to beat the bearing back on. They seem to go on a lot better than they come off. Dont forget to put the thrust washer back in between the bearing and the gear.