After a few weeks of a metalic sound from under the car when slowing down, I worked out there was play in the UJ's on the front propshaft.

However, I had to angle grind a couple of the propshaft bolts off (the ones that bolt to the front of the transfer box) due to the prop actually destroying the bolts .

I have purchased a couple of new propshaft bolts, but my question is, how do I go about fitting them, as I can't get the old ones out as there seems to be a "lip" on the transfer box so you can't push the bolts through?

Do I have to remove that mahoosive nut on the transfer box end and then pull the "flange" forward to pull the bolts out/put the new ones in?

If so, any idea how to crack that massive nut? It's a tight'un n I'm struggling for leverage.

Also, if I do remove this nut, does that mean I need new gaskets/seals for the transfer box? I'e never removed one before

I promise that is my last question of the night haha

you will have to remove 30mm spanner sized nut then remove flange then wack flange down hard on a peice of wood bolt thread down this will push of mudshield replace bolts bt606101l and relace mudshield ,its worth puttig silicon betwween flange and washer before retightening ,you could replace seal while flange is off frc7043 earlier thinner mud shield 10mm approx or ftc4939 for mudshield that is 18 mm

Might see summit in here...

http://www.landyzone.co.uk/lz/f41/transfer-box-front-output-bearing-oil-seal-renewal-81771.html

Thanks lads.

Does that mud shield actually do anything, as mine seems to have random grooves cut out of it? Just seems a pain in the backside to remove all that to extract one propshaft bolt. Can I not just slightly grind it down?

If not, I'll attempt to crack that big nut, but can't see it being easy

That tool looks good btw BB...I'm going to have to make one of those!

put it in gear in diff lock and it should come undone,mud shield does what is says ,you could cit bolts away the fit other way round ,nut toward t/box if stuck

Had problems with my front transfer output going to leak every few months even though shaft was firm and flange seal race good.I then did away with the mud shield and fitted two seals in housing,that fixed it.