Help removing u-joint caps (some progress but stuck)
 

Here are pics of the first cap I need to remove. As you can see, I've got the cap pushed out and I'm told, by rockford driveline, that i should be able to grab the cap with vice-grips or pliers and twist it out. I don't have much metal to grab and nothing will budge this cap. What should I do?

pic1 = Cap Sticking Out for Grabs
Attachment 704849
pic2 = Alternate View
Attachment 704850
pic3 = Other side Cap, recessed ofter pushing the other cap out
Attachment 704851

ALSO: On that same note, I need to remove the old motors to my AAS but the little brass screws holding the motor to the mounts are just stripping out the head. Heat, PB Blaster, or Cut? Whoever wants them can have them for free if the pay for shipping. I'm pretty sure they work, although everyone knows they're useless.

Had the same issue w/ u-joints on a chev truck a week back. The bearings are so dry of grease and the seals so dry(rubber) that they've let water in and rusted to shit. Make sure you've pressed the caps so that they'll clear the yoke and then take a touch of heat to them. They should come pretty easy.

What do you mean by clear the yoke? I've pressed the cap as far as it will go so far and now I need to pull it off the spindle and out of the yoke. Heat will still help?

is that a N/A driveshaft?.they are supposed to be NON Changeable..you "by rights" have to,or Should get another Driveshaft.(very cheap Used as Guys go to the TII driveline).although some guys have Changed them Out,somehow,and put in a Replaceable u-joint...get a grinder and Pop the sucker out that way.

You can probably saw a shallow groove in the cap parallel to its top face, and about a half inch long. Then, put a chisel point in the groove and tap the cap out. You may have to use two grooves opposite each other, so that it comes out evenly.

Good thought, I'll try that this week with a cutting wheel, but I may have to wait and get some sort of carbide bit (the caps are made of really hard metal).

I have another bit coming to grind out the rest of the staking that holds the caps in. Rockforddriveline sells replacements that are held in with a clip. All you have to do is grind out a little spot for the new clips and clear all of the staking in the yokes, or so they say.

Does anybody else think the groove in the cap will work?

I had to take one of mine out that way. I either used a hacksaw, or a die grinder with a cutting wheel. I believe either will work. Soak them with penetrant now, and they should come out easier when you're ready to try again. Good luck!

Edit: In case it's any help, https://www.rx7club.com/2nd-generation-specific-1986-1992-17/replacing-non-replaceable-u-joints-517657/

Edit again: Never mind, I see you've already read that thread.

Do the grooves, I dremelled them in on a different shaft I had the same problems with and got the whole thing apart. BE PATIENT with it, and you can get em apart.

this may not be a good idea, but can you somehow use a puller or something? like weld a big hex nut on there for the ends of the puller to grab on to, and then pop it out with the puller?