Anyone have any good advice on trying to get this broken piece out? I can email pics if it's helpful, doesn't seem I can upload them here. Thanks!
jdscott 7/22/2011I put one of the pictures as my profile pic. The bottom hole is the broken off fitting, the upper hole is where the coolant temp sensor was.
HouseCallAuto 7/22/2011Put the pics on YouTube and post the links or upload to any photo hosting site and provide the link. make sure that the pics are clear to make out what we are looking at. I believe that what broke off I have dealt with some years ago. If this fitting is a fairly large wrench size (maybe 7/8" or larger) then that is the junk white metal fitting that GM used back then and yes they break off. I was able to work with the broken off piece for like two hours with whatever worked, picking out piece by piece using a pick tool, small ball peen hammer and all the while being very careful NOT to damage the underlying threads so a new fitting would be able to be installed afterwards. Even if you remove the intake manifold you will still have to work the broken piece out millimeter by millimeter. I believe the replacement fitting may be this or similar? >> http://www.oreillyauto.com/.../C0331.oap
jdscott 7/23/2011Yes, I went to Oreilly today and that's the part they sold me. I also picked up a "heater hose coupler remover" which I can't seem to get to work for me. It's a splined fitting that connects to a 5/8" socket. Supposedly you "tap" it in and back it out with the socket wrench. Well, I can't get it tapped firmly enough or far enough into the hole for it to get any purchase, but it is making a mess of what is left of the fitting. Did they make this part out of pot metal? Good grief, it just crumbles like rotten wood. I've seen online that some people have removed them with needle nose pliers after they cut slots on the inside of the fitting with a thin hacksaw blade, being "careful not to cut into the threads". With the limited visibility and access is it even possible to be that careful? I am really concerned about destroying the threads on the housing, and it seems like you'd need some kind of impact wrench with a long shaft to pound the "coupler remover" in successfully. Any advice you can give me would be a huge help. Thanks.
HouseCallAuto 7/23/2011It is pot metal and there are no rules here for removal. What ever works for you. Pick it out piece by piece and yes you have to be that careful and you can be that careful because the alternative is awefully expensive. One thing I remember doing is making a tap. Once I had a few threads exposed I took a pipe fitting with the same threads as that fitting. I used a high speed 3" cutoff tool and ground 3 or 4 slots in the threads like a tap would have (the actual tap would be expensive to buy) and I would pick at the threads and then run the tap in further (carefully) and I would gain a row of threads at a time. It came out perfect but took a few hours over the course of a day cause you have to take a break from the monotony.