Monday, March 18, 2013

Dana 30 part 2 - teardown

The following was not photographed.   First thing that was needed was the spindles needed to come off the steering knuckles.  To do this put both spindle nuts back on the spindle.  Use the washer in between the nuts.  These are here for the gear puller.  Attach the gear puller and pull it off.  If yours have not been off since 1979 like mine had you are going to have to persuade them with a rubber mallet.  Put pressure on them then tap them with the mallet.  They should eventually come off.  At this point the axles slide right out.  Set these aside.  Next is to release the steering knuckle from the axle.   Loosen the upper and lower ball joint nuts.  Leave them on.  My lower ball joint nuts were rusted solid so I had to use a Dremel and cold chisel to remove the nut.  Now take the upper ball joint castle nut and thread it so that it is level with the top of the threads.  Now hit it with your sledge hammer till it drops.  Remove the nuts and the steering knuckle is now off.

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Next is to drain the oil from the differential. I let this sit for a couple days while I did other things. No metal came out so that is good.

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Once the oil has drained it is time to pull the pumpkin.

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Take it down off the stand and put it on a couple jack stands.  It is light enough to do this by hand at this point.  Now loosen the end caps but do not remove them.  You don't want the pumpkin flying across the room when you pry it out.  Now take two large bars and pry the carrier out.  When it has popped remove the caps and lift out the carrier.  Next we will take out the yoke.

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You will need to make a yoke removal tool.  It is just a 1/4" x 2" piece of steel drilled so that a socket can pass through to the yoke nut and 4 holes for the yoke.  It only takes about 10 minutes to make one and I never have seen one for sale.

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Here is all apart.  Now it is time to take the whole thing outside degrease and pressure wash it.  Follow that with a wire wheel and some POR-15.