Yes W.O.P., to avoid damage to the prop driver, the only safe way that I am aware of is to use a gear puller & a heat gun. Recently I used both those items to remove a VERY tight prop driver on my Saito 65 - worked a treat, the heat gun being necessary in my case.

Attach the gear puller, tighten it up with a small spanner/wrench, apply heat & wait for it to pop off. Sometimes the pop will be a loud bang & that can be a bit disconcerting. My gear puller cost me about $20 & I have now used it at least half a dozen times. It's good value.

As for your other issues, I'll pass on those & let the others answer that one.