Removing Driveshaft

[SewperDrewper]

So I need to remove the tail shaft from my transfer case to install the new driven gear I have for my VSS, but in order to do so, I need to take the drive shaft out of the transfer case yoke. Other than removing the C-Clips, how in the world do I lower that driveshaft? Thanks in advance for the help! BTW...It's a 1991 F-350 7.3l IDI 4x4 E4OD...

 

[Dieselcrawler]

remove the u bolts at the rear, unbolt the carrier bearing if u have one and pull the shaft out of the slip yolk on the tcase. no need to remove the c clips.
some tranny fluid will come out so have a pan ready.

 

[SewperDrewper]

Well here's the deal...the guy who owned the truck before me replaced the u-bolt strap bolts with Allen Heads and then decided that it would make sense to strip them out...I have tried to delicately make do, but they aren't budging and I already slipped once on one of the heads.

Since getting to the bolts with a drill to easy out them would be next to impossible with the drive shaft in the way, what other ways could I get to my tail shaft housing to replace the driven gear so my truck will at least be drive-able? I will take care of the Strap Bolts down the road when hopefully I have a little more time...

 

[OLDBULL8]

Look at the bolts closely, they may be MM or SAE or Torx.

 

[SewperDrewper]

Definitely not Torx...and a 6mm, and 1/4" are just a hair too big, but a 5mm is way to small. 7/32" was the closest I could find, and like I said, just too much play.

 

[BrandonMag]

Do the allen bolts that are stripped out have enough of a head to get a set of Vice-Grips on them?

 

[turbodiesel94]

Vice-grips or try welding a nut to the bolt head.

 

[jonathan]

my 93 was a torx

 

[RLDSL]

My 92 is a torx as well pretty sure t27 Had to use a long one to get it in there. You may have to take a torx and beat it in there and if it won't hold weld the sucker to it to get it out.

 

[jonathan]

ive done that a few times,good thing i have cornwell set and not a pos set.

 

[88beast]

cut them with a cut off wheel then just replace them and u joint both are cheap

 

[94f450sd]

hammer and chisel.put the chiselon an angleagainst the side of it and give it a few whacks and it should loosen upand come out

 

[icanfixall]

The chiesel idea is a good one but make sure the chiesel is sharp go it cuts in and turns the bolt. I hate fixing some guys mess like this... I know how to fix my own mess's but others... Nope... Plenty of "F" bombs get dropped all over the place..... Nappa sells a replacement u-joint kit with all the spaecial hardened bolts and brackets. The bolts are a 5/16 hex and you need a 12 point socket to use them... They are the same bolt that holds the injection pump to the gear... Nice....

 

[SewperDrewper]

I went to weld a socket into the hole, but my welder decided to act up and I couldn't get a good arc. So, I took it out with a grinder and everything went as expected after that. Now I'm just gunna try to grind a flat surface to the studs that are still sticking into the yoke and try to get a Vice Grip to hold on well enough to spin out the rest of the bolt.

Onto other problems. I got the tail shaft housing off and went to pull the Driven Gear off and the spline rod and bearing started to pull out. How do I remove the Driven Gear, and do I have to remove that whole output shaft?

Thanks again for all the help...you guys are the only reason this truck is still on the road!

 

[SewperDrewper]

Figured it all out!