it finally happened to me - heater fitting on intake broke

[Blizz]

now i'm struggling to get the nipple out. i tried a hack saw, couldn't get it in much. tried breaking pieces off....still a bunch in there. tried notching it on both sides and used a washer and pliers to try to back it out...it just crumbled. i bought an extractor and i can't get it to turn and i'm worried that i'm just making it hang on even tighter. i'm reading that pb blaster works well so i'm gonna get some tomorrow. this SUCKS.

[bighaas79]

pull the intake and using a hammer and chisel gently break whats left ot it up and pull it out if you are careful you wont even damage the threads.

[Blizz]

i'm hoping to avoid taking the intake off but will if i have to. it'll have to wait till the weekend. might as well do the gasket and efan while i'm in there.

[HOGDADDY]

I had the same problem on my 97 I had (was stolen while back) that piece is cheap pot metal and I bought another after I got it out should have just eliminated it.

The PB blaster and an easy out worked on mine btw.

[Zane M]

Just did this on one of our work trucks. I didn't want to pull the intake either, so I ended up cutting slots in the broken nipple with a hacksaw blade and chipping out pieces in a counter clockwise direction. Good luck with whatever route you take. Another one of GMs better ideas....NOT

[Blizz]

did you use a standard hacksaw blade? i couldn't get much of it in. i guess it's just a tedious process. i got "mod fever" and was in there doing the "hockey puck"/silencer removal mod and just barely bumped the hose. i didn't even know it was broken till i turned the truck on and saw water spewing out. after i do the efan that'll be it for a while.

[BigBlocksRule]

The good news is that the replacements carried by auto parts stores are iron/steel rather than the cheap pot metal GM chose to use. I've used small chisels and hacksaws and managed to get 'em out. I wouldn't count on PB Blaster being a big help, you're dealing with siezed parts due to dissimilar metal corrosion. I ended up buying a clearancing tap in that size on the first one I did to make sure I got the threads clean and to straighten out the screw-ups. I've loaned it out at least 20 times and used it a handful myself. Too bad you're 400 miles away, I'd be glad to let you use it...

[72freak]

This thread brings back GREAT memories!!!!!!!

[ChevLoRay]

Makes me wonder if having that nipple to corrode and break doesn't signal that the intake gaskets may also need to be replaced. On my truck, it was both. Hasn't leaked a drop of coolant since it was fixed.

[Damien]

I generally chisel it out then run a tap through it to clean the treads. It can be done on the truck. The '91 I just bought has had the coupler replaced with a nipple and a lenth of heater hose clamped in place. It seems to be working fine.

[Blizz]

what about all the pieces that break off? i'm thinking that since coolant flows out from here, turning it on for a couple of seconds should shoot out whatever falls in. am i right in thinking this? if i stick a rag in there, then i have no room for a hacksaw or i'll be pushing it too far in to be able to grab it out. also, what size tap is it?

[HOGDADDY]

Originally Posted by Damien

I generally chisel it out then run a tap through it to clean the treads. It can be done on the truck. The '91 I just bought has had the coupler replaced with a nipple and a lenth of heater hose clamped in place. It seems to be working fine.

Thats what I would do just put a nipple on it and then use regualar heater hose.

[StingRay]

I just replaced mine while doing the intake gaskets on my 92. You want to avoid pulling the intake if it doesn't need it. On my K1500 it was a heck of a job to do the intake gaskets way the hell back there in the engine compartment. You spend at least a whole day laying on your belly over the rad support. I've done worse but it was definitely low on the fun factor scale.

[Blizz]

so i called a couple of places to see if they can do it before the weekend. so far i've been quoted an hours worth of labor...one place wanted $90 plus the new fitting and then wanted to do a complete coolant system flush for $120...another place will do it for $120, fitting included and will refill it with whatever I want them to...they either use their stuff or i take them what I want them to put in it. I'm gonna go with the latter. I don't feel like messing with it all weekend and tracking down the part. Now the question becomes, what to fill it with? Green or dexcool? I keep hearing horror stories about dexcool.

[ChevLoRay]

As long as the cooling system is intact and there is no leakage and no air can enter the system, Dexcool is okay....doesn't get funky. It's an organic, which is supposed to be the "plus" factor in using it.

But, there are plenty of folks on here who have horror stories to tell. Try using the Search function and plug Dexcool into the search box. See what you get.

[bighaas79]

Originally Posted by StingRay

I just replaced mine while doing the intake gaskets on my 92. You want to avoid pulling the intake if it doesn't need it. On my K1500 it was a heck of a job to do the intake gaskets way the hell back there in the engine compartment. You spend at least a whole day laying on your belly over the rad support. I've done worse but it was definitely low on the fun factor scale.

Really? Intake gaskets on these trucks are easy. they are only like a 2-3 hour job. even factor in an hour for messing with the nipple, which probably wouldnt take that long, you can easily have this job done in half a day at the most.

I guess i recommended pulling intake just to avoid the problem of getting any debris from the nipple into the intake and potentially into heatercore, radiator thermostat, or even run thru the water pump.

I have seen guys run a regular nipple in the intake and just run the hose to it and clamp it but my question is why... the replacement is better than the original so it should never fail again and everything just goes right back together no modifing required. It really wouldnt matter either way as long as it doesnt leak when its done. lol

[BigBlocksRule]

Shop vac.

[Blizz]

thanks for all the tips and links guys. it really helped out a lot. i ended up chiseling out all the pieces to where i thought i could run the tap through but then couldn't find a 1/2" pipe tap. my bro came over and just used the replacement steel fitting. he started it by hand and used an impact wrench (on a very light setting) to drive it in. i then turned it on, gave it a couple of bursts of gas to shoot out any debris that may have fallen in. through some determination and not wanting to pay $160 for a shop to fix it, i was able to do it myself and it feels pretty good. i ended up buying two of my bilsteins with the money i saved and will get the other two in two weeks. thanks again.