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Dana 300 Rebuild Page 3

Figure 5
Figure 5

Figure 5. The easiest method to remove the intermediate shaft was found to be an air hammer with a blunted chisel bit. Since the old shaft will not be reused, we were not worried about damaging it, just getting it out. Worked like a charm. Be careful not to nick the shaft bore when driving it out.

Figure 6
Figure 6

Figure 6. Once the shaft was out, the intermediate gear came right out. be sure to get the rollers and washers that will fall out when the shaft and gear are pulled out. As you can see here, the thrust washers are heavily worn and will need to be replaced.