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StV,
I've replaced several Dana 240 rear ends over the years. The last was in Oct. I just get the rear end up high enough to easily work on it, set it on some good solid jack stands and get at it. I make sure I have a long breaker bar and BP B'laster to deal with the corroded bolts, brake couplings and fasteners. It's not really a bad job to swap out the entire piece. Good time to replace the T rod, trailings, track rod bushings. I replace the inner axle seals,brake pads, rotors (if needed) and brake hardware as well. A Bentley 240 manual is a very good thing to have on hand for this and zillion other repairs. It's can be a bit of a PITA at times, I struggle with things like the parking brake cable connections, but over all not a bad job. Stuff like the coil springs are easier to deal with than you might expect. Removing the axle exhaust pipe provides a lot more clearance when moving the old rear end out and the new it. I took the evertyhing from the cat back off in the last job as I had new exhaust components to install. You'll want to get the proper gear ratio for your tranny (Auto or manual). An assistant is helful when actually removing or putting the rather heavy piece in place. Do get a Bentley manual if you plan on doing any amount of repair work yourself. An invalauble tool.
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