As I recall from my materials class from engineering school bending the metal will add stress and make the metal harder but less tough (more brittle?). Unless it is dropped from an airplane though you probably will never see enough force or torque to break it.
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This type of pulley holder works great:
http://www.google.com/products/catalog?q=clutch+fan+wrench&hl=en&prmd=ivns&resnum=3&biw=1440&bih=747&um=1&ie=UTF-8&cid=1543334190707786588&ei=teATTdfyGYP58Aa12K3oDQ&sa=X&oi=product_catalog_result&ct=result&resnum=1&ved=0CFkQ8wIwAA#
I've never had that work. I have a universal pulley holder that makes it about a 10 second job and no worries about wrenches flying across the garage at high velocity. An air hammer will get it off too.
You can buy lug nut extractors to use with an impact but finding one in 27mm/1 1/16" may be difficult/expensive. You can also hammer on a close fitting impact socket. Or just take it to a shop and pay them $20 to get it off.
Any hydraulic fluid will work fine. I'm not sure about the castrol brake fluid and Lucas swill combo mentioned above though. Also the pumps mainly fail at the paper gasket which has nothing to do with the fluid just poor materials.
you don't need to drop the tcase to do that seal. You could try a seal sweller like white shepherds but it sounds too far gone, you may have a notch cut in the shaft too.
yes it has been spoken about over at other forums. I've not heard about anyone that has actually installed. unfortunately if you want info on it you have to go through the biggest tool on the planet.
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