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I am trying to change the transmission fluid for the first time in an '04 Z06. I have used an impact gun that puts out about 200 lb-feet of torque and slathered it in penetrating oil. Hasn't budged. I know the next step is heat, but am reluctant to put a torch to the aluminum trans case. You're thoughts please.
Just don't keep the torch on one spot for a prolonged period of time. Don't heat the bolt head, but the case around it. If you have any header wrap you can shield the bolt head with that as you don't want the bolt to expand if possible (you probably already know all of this, so I'm not trying to talk down to you, just throwing it out there in case.)
Have you tried a breaker bar or just the impact wrench? Just curious, I need to do this soon.
I'm a little nervous because my C4 with ZF 6 speed had the same issue where I could not break the bolt loose with the 17MM Allen. Heat was most definitly my friend in that situation.
Agree with the comment that a torch on aluminum is a bad idea. I would also offer that using an impact wrench on the bolt probably isn't doing the trans case a lot of good either.
I've always had good luck with PB Blaster and a long lever - and patience. A breaker bar with a pipe on the end has never failed me. Ensure the socket is fully engaged with the bolt before you start twisting. Take it slow, and keep the bolt lubed with the Blaster. Adding heat with a heat gun will help.