That thing is stuck!! The Dana sight says to use a spreader to actually warp the case and pull it that way. . . I'm pretty sure we all don't have a spreader or magnetic dial. . . but I now you guys have pulled these things before Bestow upon me the knowledge necessary to complete my task O great FTE forum Gods!

 

One way that sometimes works for me is to put a box wrench on one of the ring gear bolts and turn the pinion until the wrench rests on the diff housing. Make sure that the rotation is TIGHTENING the ring gear bolt. Now, get the socket that fits the pinion nut and your biggest breaker bar/ratchet/cheater bar (think replacable i.e. Craftsman) and give it a good crank. The idea is the box wrench will transfer the force from the pinion to the case and push the carrier out of the housing. You may need somebody's help to make sure that everything stays where it needs to be. Do this carefully as things can slip or break and fly in unpredictable directions. Also, the carrier could slide more on one side than the other and get even further stuck. I have used this technique the most in junkyards where I don't have the proper case spreader, etc. If you are not comfortable with this procedure, you can also build a case spreader that is basically a heavy steel frame that bolts where the dif cover is attached on each side. Either the top or bottom of the frame has a nut and bolt arrangement that expands the frame as the bolt is turned. Make sure that you use strong bolts (grade 8) to secure the spreader to the housing. It doesn't take much movement to free the carrier but it will take a fair amount of force to spread the housing.