So two of the nuts holding my front drive shaft to my transfer case rounded off, so me being me I cut them off with a sawzall. Now my problem is that I can't get the bolts out of the trans case to change them out. Anyone have any suggestions on how to get them out?

 

If you cut the bolt heads off, you probably have enough left to use a bolt extractor or vice grips. Heat it with a torch and remove them. If you don't have a torch, soak them with penetrating oil for a day or so and give it a try. If they don't come out easily, STOP and find a torch so you don't make things worse.

 

You'll need to remove the transfer case rear output flange, remove the external snap ring (#12) from the back side that retains the bolts, and remove them.
Might as well replace the output shaft oil seal while you're at it.
Be sure to fit a new nylock nut when reinstalling the flange.

 

Wow that looks a lot tougher than what I was hoping for....

 

It's not too bad. Remove the countersunk screw from the brake drum to remove the drum from the output flange. Then just remove the output shaft nut, etc., as described above.
You may have to slacken the shoe adjuster to get the drum off.

 

Split the nuts next time... much less hassle.

 

Tom not trying to beat a dead horse here, but where is that countersunk screw at? I'm planning on doing this job this weekend, btw, so I'll let you know how it turns out.

And thanks for the help! I couldn't have this without this post!

 

Ok so I've just crawled under my truck to look at taking the front output flange off of the transfer case. But what I've found is that the self locking nut is huge! Anyone have a size on that thing so I don't have to run to the store and buy two or three different sockets. And the rave manual doesn't look the same as the diagram above. Best to follow the RAVE or the diagram above? I'm hoping once I get into this it's all pretty self explanatory.

thanks guys

 

Ok I hate it when people do this on forums, but I'm bumping this bc I can't find anything about it with internet searches and I need to get this done soon. Anyone have any experience taking this part of the transfer case apart?

 

I don't have experience, but it looks fairly simply. Remove the large nut holding (#10) the flange to the T-case. Then, remove the snap ring (#12), then the bolts (#13) should come out with the flange (#8).


Don't worry about the seal, its pressed in there and won't ,"just fall-out".