Gear swap
On flat level terrain place the front axle on stands, Remove the hubs, spindle nuts and remove the rotors. Look into Mr. N's dana axle site for very good pictures of this process. I highly recommend buying a spindle nut tool.
Once the whole outer axle assembly is removed to include the shafts you can remove the diff cover and drain the fluid. Now many will recommend a housing spreader, I never used one and it was fine but I heard it can make the whole thing go easier. Remove all of the bearing caps and bolts, mark/organize them so they can go on the same they came off.
Once the carrier is unbolted run a rag like a small terry cloth or a few red shop rags in between the pinion and the ring gear. This may take some muscle, use something like a big ass pipe wrench on the pinion yoke to turn it. This will pop out the carrier.
Take the carrier and press off the old bearings. Do this carefully as to not hurt thee bearings or the shim pack under them. remove the shim pack from the old carrier and measure it. Take a die grinder and grind out the inside of the old bearings to make them slide on and off the carrier snug but not requiring a press.
Now this is where you will need a new carrier, some will say use thick cut gears and this may work for others but I say don't waste your time. Get a new open carrier and install the ring gear on it.
Put the new bearings and shims in for the pinion gear and put on your pre measured shims and old setup bearings on the new carrier and plop it in the axle. Check the pinion depth and the gear tooth pattern and make adjustments as necessary. Keep doing this until you are satisfied and once it all looks good put on the final bearings on, you should only need make a few more adjustments at this point.
This is pretty watered down and I left out all of the specs, you really ought to buy an install book from Randy's ring and pinion.
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