A6 rear differential fluid change

[Peter Golledge]

Try using a propane torch to heat the area around the plug, it will take
quite a while (say 3-4 min) to build heat.  I've used this on various stuck
fasteners and it has worked like a charm.  The thermal expansion does
wonders for breaking loose threads.  Don't be afraid to let things cool,
apply more penetrating oil and heat it again.. it will smoke a bit though!

-----Original Message-----
From: quattro-bounces at audifans.com [mailto:quattro-bounces at audifans.com] On
Behalf Of Kunz, Bob
Sent: Wednesday, April 15, 2009 11:48 AM
To: Quattro List
Subject: A6 rear differential fluid change

Need your collective wisdom, BTDT type of stuff.

Patient is a '99 A6 Avant new to the household (120K miles). Wanted to
change out or at least check level of the rear fluid but the fill plug is
really solidly stuck in there. I tried perhaps 200 ft-lbs of torque with
simple ratchets and no movement. Soaking in liquid wrench for a few hours
and still no movement.

I was going to take the brute force method and apply an impact wrench to it
but then thought that might crack the case and I certainly don't want to do
that. Any other thoughts to get the fill plug out? Or have others applied an
impact wrench with success?

--bob

'86 5Ks Avant
'99 A6 Avant
'02 TTQR
'07 Q7 4.2P
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