Curmudgeon wrote:
Lots of good suggestions! One trick I have used a few times (you need good access to do this): put a box end wrench over the bolt head, pull on the wrench in the direction of removal, then hit the top of the fastener with a hammer. Obviously do not use this on a stud/nut combination since it will mushroom the stud tip, thus multiplying your problems.
The "short sharp shock" trick is key to getting the halfshafts out of a Miata diff
Get some pressure one with two prybars and just tap the side of the shaft with a hammer. The shockwave through the metal is what pops it free, I think. Whatever, it's pretty cool. You'll never get the shafts out of an aftermarket GURU diff any other way. I can see this working elsewhere, that's a good one to try. You usually don't have to hit the parts hard.
If you want a masterclass in removing crusty fasteners without damage, get an old Land Rover. Not only do you have the usual rust, but you also get galvanic corrosion, lots of mud buildup and the odd Whitworth to keep you on your toes. And you soon discover that massive leverage is rarely the answer, as then you find yourself looking for some oddball British fastener after you've ripped the old one apart.