How the heck do you get the front drive shaft off!!!

[FATCAT]

Need to have the U-Joints replaced on the front drive shaft of my 4500. The drive shaft has flanges on both ends. The front end to the axle has teeth and the other end to the transfer case is (I assume smooth).
There are just 8 bolts (4 on each end).

I removed all 8 bolts and tried like hell to get that thing off. The shaft does not collapse (must be one solid piece even though there is a rubber boot midway on the shaft).

No matter how much I pounded on the axle flange on the shaft end at the transfer case it did not budge!
After about 45 minutes of this I put the bolts back in and will probably have to take it to a shop to have the drive shaft removed and U-Joints replaced.

Is there some hidden bolt within the double-cardan joint at the transfer case end??? Some hidden set screw holding the two flanges together other then the 4 main bolts?

What is the secret to getting this damn thing off???

 

[mfurrh55]

On my 07 I just used a huge flat end screw driver and pried it off, you might need to Jack up the front end of truck to relieve some pressure on it

 

[cerberusiam]

There is a splined connector under the boot, the front part slide in so if with drop off the front flange and the rear flange has a small lip to hold it centered. 8 bolt is all there is, sounds it might be seized from corrosion in the splined shaft.

 

[seafish]

post deleted

 

[FATCAT]

There is a splined connector under the boot, the front part slide in so if with drop off the front flange and the rear flange has a small lip to hold it centered. 8 bolt is all there is, sounds it might be seized from corrosion in the splined shaft.

So if i pull the 4 bolts from the shaft to the axle connection, if i can find a slot to jam in a large screwdriver i should be able to move it back into the rear shaft? I'll give it a try this weekend.
The front shaft was off the truck last September when i had a South Bend duel disk clutch installed. That is when the mecanic said the ujoints were getting worn.
I'll try jacking the front end up as well.

 

[cerberusiam]

Yes, pull the 4 stupid torx head bolt son the front flange and throw them as far as possible after you get flanged cap screws the same size and length.

A good pry bar and the front part of the shaft should slide back for enough to drop off then the rear one will come apart after removing the 4 bolts in it.

 

[MGreer]

If the torx bolts are the same as on a 3500 they are M8 - 1.25 x 30 grade 8.8 flange bolts. I got some from Lowes but I only used them to pull off the yoke. Fastenal would probably have a better grade bolt.

 

[davo727]

I had to smack mine around the other day to get it off.

 

[FATCAT]

Yes, pull the 4 stupid torx head bolt son the front flange and throw them as far as possible after you get flanged cap screws the same size and length.

A good pry bar and the front part of the shaft should slide back for enough to drop off then the rear one will come apart after removing the 4 bolts in it.

The 4500/5500's don't use torx bolts. They are using 16mm cap bolts for both front and back drive shaft flanges.
I'll give the pry bar a try this weekend and hopefully it will work.
Like I posted earlier, the front drive shaft was off the truck back in Sept. when I had the South Bend Duel Disk installed (the Duel Mass Flywheel crapped out after only 75,000 miles!).

 

[EricViviano]

the Duel Mass Flywheel crapped out after only 75,000 miles!

That's actually great life for the POS dual mass setup.