This may not work, but can you disconnect the drive shaft at the front diff, and then split the shaft at the splines, and remove the transfer case. Then you should be able to get to the bolts better, and remove them.

 

Why are you removing the drivesaft? You dont need to in order to install the SYE...

But i'd be inclined to fix the issue now rather than later. Pll the transfercase down with the front shaft bolted up still.. then use what you need to and remove the bolts.

 

now i was told i did so i can remove the chain an sprockets. i was told i can not do it with out removing the front driveshaft. also it gives me piece of mind that i can remove it if it breaks on the trail. i also have a 32" driveshaft (pulled from a grand cherokee auto) for it cause of my tall lift, the 29" one i have up there now is at its limit!

 

dont try and cut them off just try and break them loose by hitting them at the base the direction the go to loosen up

 

cant use it slip yoke dont work no mo

 

Try adding some heat to weaken the bolts and the using a chisel and BIG hammer those little suckers are made out of harden steel

If that don't work get a hack saw for reciprocating saw preferably and cutting off the heads of the bolts usually when you get the tension off the bolts they come right off

good luck stuck bolts are no fun i hate rust

 

Wait... do you have reversed Torx bolts for your front driveshaft bolts? Could you be confusing them as being rounded off?

You need a 12 point wrench on them.

You dont need to remove the front output. Just snapring and gear along with chain.

Check youtube, google images etc. Search a write up or something so you know whats going on and not listening to others who are clueless.