Help replacing my '97 AWD transfer case

[jiazi]

HELP!!!! I have removed the front drive shaft with no problem and got all of the bolts out of the transfer case. I CANNOT get the rear drive shaft bolts to break loose. I have soaked them 3 times and used an air rachet and still nothing. How can I get these bolts out. Is heating these bolts going to help and is this going to be a probelm being so close to the fuel tank.
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[gmanpaint]

As long as you have no fuel leaks, you will be fine with a simple propane torch.

Try to tighten them first before loosening. Sounds weird, but sometimes it helps.

Tapping them can also free them up sometimes. Use a drift, or a 1/2" drive extension, and tap the bolt heads with a hammer.

A good 1/2" drive impact gun (with extensions on it to get to it) and the 12pt socket is the best way for these stubborn bolts.

Good luck!

 

[IZwack]

If you're worried, then aim the torch towards the passenger's side, as in away from the fuel tank.

Another thing worth noting is to park the vehicle on level ground, chock off the wheels, and set the E-brake. This will relieve drivetrain stress that's being exerted on those driveshaft bolts.