I've removed/installed the rear Dana 20 Output shaft. Can anyone confirm the front shaft removal and installation works in the same manner? I am leaking oil from around the seal...I think Can I service the seal without removing the shaft?

the seal?
There is no real removeal of much
Pull the driveshaft
pull the center nut that holds the yoke on
tap with a hammer, yoke comes off.
take a seal ripper (sold at every parts store) remove seal, install new seal, put yoke on, put nut on, put driveshaft on

Alright, the seal is easy. I want to pull the entire shaft...check the bearings/wear/etc. Can you confirm the process for the Front Output shaft is the same as the rear? Do I have anything to worry about?

The front is a bit more tricky as you need to pull the rear bearing off of the shaft in order to pull it out. Once that bearing is off, it is pretty straight forward.

I thought that was the case. I knew I heard that somewhere. :)

So to remove that bearing...Remove the case...What's the best way to do this?

:rasta:

1) Remove the front yoke and the inspection cover.
2) Remove the front bearing retainer and replace the seal.
3) Remove the rear bearing retainer (cap), and put the shims under it in a safe place.
4) Thump the threaded end of the shaft (carefully) to unseat the rear bearing race, and remove the race.
5) Remove the snap ring that's between the front bearing and the front drive gear.
6) Pull the shaft out through the rear hole.
7) Remove the front bearing.

Theoretically you don't have to remove the clustershaft from the center of the case to do this. Not sure how tricky it'll be to get that snap ring off with the clustershaft still in and the case installed in the truck, but it's probably doable with some patience.

Personally, I'd just replace the seal :D

Chris