Transfer case output shaft flange bolts, can't remove - tips

[esclamada]

Tried to replace my transfer case output seal today but got in a situation where I can't even take out the driveshaft. The 4 bolts that hold them (12mm) is way too tight that even my tornado impact wrench at 600ft/lbs of torque can't budge them. I soaked them in pb blaster and it just wouldn't come out loose. Although it was torqued at 18ft/lbs I think the loctite made it impossible to loosen them. Any ideas on how to deal with this? Another issue is the big nut in the output shaft flange that is torqued to 262 ft/lbs, with the loctite this seems impossible for a weekend DIY mechanic.

Thought of using heat but it is very close to the gas tank,might be a recipe for disaster if I'm not that careful.

 

[2TimingTom]

You're sure you've got it set to loosen, right?

The problem I ran into while trying to do my output seal was the nut on the output flange was insanely tight. And so I took it into a local 4x4 repair shop to have them do it and they informed me that my transfer case bearing was screwed up. $1500 later I had a new transfer case output seal..... and a rebuilt transfer case.

 

[Turbo teggy]

Try using a torch.

 

[esclamada]

I assume that loosening is counter-clockwise (the standard direction) It's possible that something might have cause the seal to leak (such as the bearing in your case) but with an 8yr old 106k miles truck the seal could age badly.

Was thinking about the torch but it's quite scary when the gas tank is just a few inches away. Trying to research the safe way to do it, or else bring it to a shop.

 

[Foxracin]

If by tornado impact wrench you mean the little blue electric piece of junk then no its not going to work. You need a real air impact to get them. Can also get them with just a wrench and a pole on it. May bend it though.

 

[esclamada]

Got this figured out. I soaked the bolts with PB blaster 2 days before I worked on it. Using an impact was a piece of cake for these bolts. For the 30mm nut I soaked it with PB blaster went for a drive to borrow the metric axle socket set (I have a 1/14" socket which doesn;t fit snugly) and the 3 jaw puller. Once I'm back from Advance Auto, I used a heat gun on the 30mm nut to boil the green loctite and used my air impact to loosen it. I got it after 2 tries with heat and impact (It's probably a minute at 1000F)


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