Hi everybody. Went to rebuild my front propshaft this morning and got stopped before I got started. Could someone please tell me the best way to get the prop shaft off?

I started at the tranny end with a 14mm socket but that wouldn't fit/clear so I went to a 14mm box wrench tapping it with a rubber mallet. Got three bolts off before I rounded off the 4th. Stopped me dead in my tracks that one did.

Just to see if I could get the axle end free, I tried the 14mm box wrench on those bolts and no luck. They are super tight and if I tap with a mallet, I risk rounding off another nut which I don't want because I am not sure how I am going to deal with the rounded one on the back yet.

A little advice please. I have liquid wrenched everything and tried what I could. I'm not the smartest guy in the world but I did get my plug wires changed without removing the air intake, bending a screw driver or asking a wife or kid to do it. Just permantly scarred my hand, but I did it.

So two questions. 1) what is the best tool/method for removing the front prop shaft (both ends) and 2) how in the heck am I going to get the rounded 4th nut off?

Thanks fellow Disco lovers.

2001 DII - 102K - with Precision 344 u-joints and a Precision 617 centering ball going in if I can get this damn prop shaft off.

 

Cut them off, use a dremel to split the nut. You don't really want to re-use them anyway.

 

it's a 9/16".

spray the propellant/lube, let it soak, and then squeeze the crap out of it with vice grips. but sounds like you might need to dremel.

one they're off, replace the nuts with nylon lock and metal (no zinc).

 

Ideally use 6 point box end wrenches on the nuts. Open in is fine for the bolts as they are mostly held from rotating by the input and output flanges.
Yes on some sort of cut off wheel on the one you rounded off, though I guess an attempt with a pair of mole grips is worth a try.

 

"Got three bolts off before I rounded off the 4th. Stopped me dead in my tracks that one did."

The Antichrist posted this link in the post next to yours, looks like a great instruction set.
http://www.discovery2.co.uk/propshafts.html. You will love this....

I particularly thought of you when I read the line "So, to remove the front shaft, simply undo the 4 nuts and bolts at either end of the shaft, and it will simply come away." Seriosly though it does look a good set of instructions.

BTW depending on which bolt is rounded off you could try a chisel and cut at 90deg to the flat then use a heavy lump hammer on the chisel once you have cut a groove. I know it's not all that clear but if you get my meaning it works to loosen the bolt/nut.