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Plan on having half the clips break even with the tool, as mentioned above you don't need them all.

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. .

That is about a 30 minute job (with a beer break). A long ratchet or breaker bar is useful to loosen the belt.

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.

use a 3 legged puller it will pop the hub right off the axle.

pretty common for most vehicles.

sounds normal, I think the full line is too high on the exp. tank.

We shall see...

If anyone is interesting I bought these hub centric spacers from ebay...

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.

lucas foams in gear boxes. I would just use a thicker gear oil like rotella 85w140.

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.

Do they still have the cellophane gasket with the alien jizz sealer or have they improved the pumps? My thought is that a DII OEM pump is destined to fail.

Seafoam is just isopropyl alcohol and pale oil. I kind of doubt it would affect thing so much, actually I kind of doubt seafoam does anything in the gas tank as gas already has 10% ethanol in it (unless you added over a gallon). Sounds like you have a MAF problem maybe.

I just used grey RTV, think it was the stuff for gear oil I had laying around left over from sealing my transfer case. I let it cure 36 hours before doing the final torque on the bolts. If this one fails I may try the gm pump adapter.

Well its been over 4 months for mine and it been below freezing for a week now so we will see.

I just opened mine up and rtv'd it back together, works fine. There is some place that is selling a GM PAS pump conversion.