Output shaft seized on transfer case spool?

[apickle]

I've got a car in the garage that needs what sounds like a new output shaft/spool. However, it seems like the shaft is stripped enough that it will spin for a mm or so, and then jams in the spool. I get a sharp "clunk" from that area of the driveline when backing up, and again when taking off in 1st gear. Attempting to remove the transfer case, it's fully seized onto the output shaft and absolutely will not budge. The car still moves under its own power perfectly fine, but I can't seem to unstick the shaft from the spool.

Any suggestions?

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[stealthee]

Did you miss a bolt?

[apickle]

I've removed enough transfer cases to not miss any bolts :)

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[RealMcCoy]

Probably seized on the dowels, not the shaft. You have to be really careful where you pry on to get it loose. More than one bellhousing has been cracked over the years by prybars...