Ok, so I finally got the transfer case and front propeller shaft loose. I've got some photos to attach that will hopefully make this an easier process for everyone else in the future. Of note, the REAR propeller shaft is not compressible/expandable, whereas the FRONT propeller shaft is - by an inch or two I might add.

The overall solution was to move the transfer case rearward with taps from my 3lb hammer. In all honesty, I was trying to create enough room for the propeller shaft to just fall off when I noticed the T-case had moved about an inch! That isn't where I sprayed the PB Blaster, but I'll take it!

Well, at least it was movement in the right direction. So I continued with the pounding (after getting my wood blocks positioned to prevent anything more than an inch fall) thinking the shaft would let go at anytime! But alas, it was not to be.. The shaft remained in place.

Eventually the transfer case slid off the transmission shaft and onto my blocks! Hah! Success! Except......... that damn propeller was still attached AT BOTH ENDS!!! I actually said to myself - "That is impossible!"

I resisted the temptation to attached a tow strap to it and get a running start with my 8000lb truck and see what happened. Instead, I pulled the transfer case to the side of the truck and braced my feet on the frame and pulled with all I had until - clank! The differential side let go! I hauled my Great White Whale into position for photos. Here it is:


As you might notice from this shot of the Front Propeller - Differential side - There is a PROTRUSION that prevents the shaft from falling off!


So, I began working on the transfer case connection with a cold chisel and my 3lb hammer and after a dozen or so good whacks - clank! It too fell off:


Notice the crusty, rusty, flaky stuff that was apparently holding it all in place. Note how both ends have PROTRUSIONS. That certainly didn't help my efforts of removal, but here is the real kicker. The shaft is compessible/expandable. So, and here is the part to pay particular attention to, no matter how hard you hit the shaft from the side, because it is constantly trying to expand (that would prevent disconnection under flexing) - it is designed to NOT fall off. Here it is compressed:


And here it is expanded:


And this was only at one end, it does the same thing at the other.

Here is my advice, FWIW: Removed all bolts from front propeller shaft ends and then compress the shaft for easier removal. Think about looping some high tensile wire or cable around the shoulder end of both shafts and twist the slack out with a heavy duty tool until the compression pulls one end loose. Or you could also removed the bolts from the transfer case and slide that rearward. Either way could work depending on how "stuck" the ends are.

Any questions or suggestions? (It was a hard learned experience.)

Sam