So I decide to rebuild my front DS. I got all of the parts, crawled under the Disco and the nuts that hold it to the flange are rounded off, I'm guessing from a previous repair. I managed to use Vise-Grips and get the front loose, but the end in the TC seems hopeless. I tried PB Blaster with Vise Grips, hammered on a socket and tried to get it off with the impact, no dice.

Reading online there are various ways to maybe get it free. I'm leaning towards a nut splitter, but I'm not sure I have enough clearance to get one in there. I guess I'll buy one on the way home tomorrow and try it. Anybody else got any ideas?

 

On the DI they used nylock nuts and you can melt the plastic with a small torch and the nuts will come right off.
I do not know if they also used nylock nuts on the DII or not, if so maybe give it a try.

 

I'll have to look at the nuts I pulled off the front tomorrow. They are as soft as lead. I'm soaking them in PB Blaster overnight and going to tackle it again tomorrow evening. I did some in depth searching on the forums and found others with a similar issue. May try dome nut extractors, then a nut splitter if that doesn't work.

 

I used a dremel tool and notched the end of the bolt to get a large screwdriver on it. Was able to get enough leverage with a closed end wrench to get it off.

 

I have not checked the clearance under there but you may try to spot weld another nut onto the stripped one. I have doen this with other bolts and it works great.

 

The Disco IIs use nylock on the drive shaft (at least they are used on my 03) so using a torch should help.

 

X2 nylocks, they need to be replaced anyway with the shaft

 

Or go to Sear or one of the Tool Wharehouses and buy a gut rounded nut remover.

 

Thanks for all the replies guys. I'm gonna stop by and pick up all new nuts and bolts on the way home. Gonna give her another go tonight. I'll let you know how it goes.

 

Success! I had a set of Craftsman rounded nut remover sockets. Worked like a charm. Mods can mark it as FIXED.