trying to get more clearance so my y pipe will fit- disconnected the front axle end but am having difficulty at the t case end. Tried vise grips but don't have the grip strength to make tight enough so won't spin.. Tried 5/16 7 mm 8 mm etc they are either too big are too small. Any help would be appreciated, thanks

 

Pretty sure the bolts are 5/16.. Try heating the yoke around the bolts with a propane torch for a bit, but be careful not to melt the output seal.

 

thats my problem...can't find a wrench size that fits..5/16 too big 7mm too small etc.. tried I bolt remover kit I have, same crap. almost to the point of saying the hell with it and grinding the bolt heads off and pulling it that way

 

the rust on the bolt probably shrank the end of the bolt down. if it gets bad enough just take the 7mm and hammer it on. it should come out then replace the bolts(they have a kit at the autostores for it

 

i understand what your going through. i used a lot of lube, heat and a pair of vice grips. it took an entire day to get 4 bolts out without breaking them.
i replaced the them with grade 8 bolts that take a hex key, then i ran into a second problem. stock hex keys will not go into the bolt because of clearang issues. i cut half of the end of the key and it worked great.

 

a ratchet won't fit.. got one out using 6 point 5/16 1/4 drive socket with mini breaker bar to crack lose and then finish with a wrench, but broke the breaker bar..went to lowes/ sears to get new tools..a couple options now..even discovered that side terminal battery remover wrench are 5/16 6 point! hope got this resolved soon..the dakota isn't my only project

 

The bolts are old and worn out. Cut them off and replace with new

 

got them out in 2 seconds with craftsman go thru socket set.. definitely a tool set that earned its keep to me now! but I think the front u joint is shot..grease barfed all over it...hard to change? never did one.. my friends always used a vise to do one

 

It can be done without a press or vice its just a real pita

 

my friend thinks its fine, just someone overgreased it...didn't clunk or anything