i don't think so. you can't get the diff out until you remove the inner (intermediate) axle.

from the service manual. it says to remove the seal. does it look like that would help any. would it go out the axle tube instead of the cad hole. on my d44 it came out the cad hole.
http://www.rm-indy.com/wavefiles/2001ramsrvcmanual.zip

page 3-61
REMOVAL - INTERMEDIATE AXLE
(1) Remove the vacuum shift motor housing.
(2) Remove the outer axle shaft.
(3) Remove the inner axle shaft seal from the shift
motor housing with a long drift or punch. Be careful
not to damage housing.
(4) Remove intermediate axle shaft and shift collar.
(5) Remove the intermediate axle shaft bushing
(Fig. 23).

 

Thanks for the manual, Passenger side seal has been removed, and still no luck getting the collar out.

From the manual it looks like it should come right out, but it's not coming out.

If I remove the center pin in the differential, I believe I could slide the intermediate shaft more to the drivers side so that I could remove the collar. How does the center pin come out?

 

The center shaft appears to be held in by a roll pin.... probably have to drive it out with a hammer and punch.

 

you dont need to take out any center pin....only the shafts need to come out, then the 4 bolts holding the bearing race pieces....i used two prybars, and pryed until my veins popped out of my arms, and it finally slide out....watch out ITS HEAVY....have something under it.

also have fun with seating the pass. axle seal....ive gone through 8 seals, and about 10 hours worth of labor, and mine still isnt in....and i have to take the carrier back out now....driver side seal i got seated in less than 2 minutes lol...

 

How easy did the shift collar for the CAD come out for you guys once you removed the CAD motor and the passenger side axle and inner seal?

The collar gets hung up on the intermediate shaft and the housing. The shaft is pressed all the way in against the center pin in the diff carrier.

 

I really need some input here guys. I took some photos, as you can see the collar gets wedged between the locating pin in the end of the intermediate shaft and the CAD housing. The intermediate shaft is as far left as it will go (It's up against the cross pin in the diff).

The only other option I can think of is to remove the cross pin in the diff so I can move the intermediate shaft more to the driver side and pull out the collar.



2nd pic just shows the collar laying in the CAD housing. How easy was it for everyone else to pull the collar out on your Dana 44 axles? This is on a Dana 60 front of a Ram 2500.

 

The manual isn't real informative..... there isn't a specific procedure to service just the collar, and it only says to 'remove it' along with the intermediate shaft on that side. Looking at your pics, I can't really tell if it would fit thru the outer axle tube?

Barring that, can you remove the shaft thru the outboard side, and THEN take the collar out?

 

The collar does not fit down the tube, and the shaft won't come out until I remove the collar. I'm planning to pull the cross pin in the diff carrier in order to slide the shaft over to the driver side enough to get the collar out.

I'll report back on how this approach works.

 

Problems persist. We can not get the roll pin (split pin) to come out of the cross shaft. Does anyone know if the whole for the roll pin that runs through the cross shaft and carrier is tapered (i.e. the roll pin only goes out 1 direction?)?

I'm open to any other ideas or suggestions you guys may have. Please don't hesitate.

 

I wish I could help, but the Dana 60 is apparently a little different than the Dana 44, the intermediate shaft is anyway.

Here is a Dana 44 intermediate shaft without the center pin that is holding you up.


On the 1/2 ton axles, as soon as you pull the passenger axle, the shift collar is ready to roll right out.