Transfer case - front axle removal question

[turbotaguy]

Ok, I bought another 1354 transfer case to replace my damaged unit. I just got started on the job and am already m-fing the truck. I have 2 questions:

1) Is it necessary to remove the front driveshaft from the axle side first, before you remove from the t-case side? I think the answer is yes, but wanted to verify

2) Any special method to remove those 4 evil little bolts on the front driveshaft at the front axle end? I have already broken 2 torx T27's on them and don't have any of them removed. Would it have killed them to allow clearance for a socket?

I'd appreciate any advice. Thanks.

 

[4x4junkie]

It doesn't seem to me you would HAVE to remove the axle side of the driveshaft to get the t-case out, though it would likely make things easier.

You sure that's the right size torx though? (the ones on mine are T-30s)
Also, Ford did use Loctite on those during assembly, some heat does help them come out easier.

 

[scotts90ranger]

yep, a little butane torch will make that job a piece of cake, same with the other driveshaft bolts.

a tool I've found VERY helpful to get those torx bolts out is one of those ratcheting drivers, basically a ratcheting 1/4" wrench with a stop to put the bits in, very handy, these are like $4 at Harbor Freight

 

[Nhaz]

Get it nice and warm. Most drive shafts bolts have red locktite on them, you have to warm up red locktite or it will never come out.

Put them back with red locktite too => you never want those bolts to even think about moving.