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Since it seems to be a slow time here, I wanted to share the most recent struggle I had doing something that should be mundane work on my Turbo Coupe.
It has been long past time since my rear axle needed to have its fluid changed. While I realize this is not vital, when you have a car that's 40 years old preventative maintenance becomes paramount.
I have done this several times in the past, and it was not an issue. This time was different.
(WORD TO THE WISE: Before starting this job, make sure you can first get the Fill Plug loose so it can be removed.) I did not.
I guess you can imagine what happened next. I loosened the cover plate, drained the oil, cleaned both surfaces of the housing and the cover plate, in preparation for the silicone applied as the gasket.
Then, at least I did one smart thing--I thought it would be a good idea to try to remove the fill plug.
It would not come out. I tried using a big breaker bar; using a Ryobi torque driver. It would not budge. I heated the plug using an acetylene torch. I spayed it liberally several times with Superzilla.*
None of these things worked. After a week of working with this part-time, I gave up. Instead, I drilled a hole in the cover plate, spot welded a nut to the inner side of it and installed an M10 bolt with a gasket, the end of which I cut off so it was flush with the nut. That's now my fill hole. The downside of this is you can't actually measure how much fluid is in there. I figured at some point I would take it to a garage, have them put it on the lift and then try to get that fill plug at least loose.
I could drill it out, but I don't think it's that vital to have.
*I saw this product advertised whilst watching an SEC college football game late one night (apparently it's big in the South). I visited the Superzilla website and was impressed. I wanted to rebuild a spare turbocharger, and I thought this might come in handy. Of course in the process of doing that, part of the housing has gotten wedged inside another part due to the extreme heat. It's recommended to apply WD-40 and pound on it until eventually you knock it loose. Since I have rebuilt turbos several times I've gotten used to doing this. But this time I used Superzilla and it came apart mostly right away.)
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