Shade tree mechanics at their best. Your opinion please!

[Gene]

I agree. ez out is the best option.

[slomotion]

When you re-assemble the parts, a little Never-Sieze or teflon tape won't hurt.

[KevsClassics]

Originally Posted by baja

They make a tool for removing that. most auto stores have it.

X2.
The right tool for the right job makes life easier.

[OhOneWS6]

Originally Posted by dfwright

Wow... I still have the original on my Suburban. I think I'll go pull it off and replace it before I end up in the same boat.

Be prepared. 95% of the time they break if they are the original pot metal piece. The saw method is by far the easiest way to get the broken one out. You will be surprised at how easy that soft metal is to cut and how easy it is to knock the pieces out after you cut a slot or two in it.

[Rooster's 67]

WOW.. all I can say.

Heres Link to the proper removal tool http://www.google.com/products/catal...ed=0CEkQ8wIwAg

And any part store that calls itself one should stock the aftermarket Steel Fitting. and they should be able to cross this part number:
ACDELCO Part # 1530900
or
DORMAN Part # 800401

Do it right and be done with it,
you'll spend more on eaze-outs and a tap, and other crap.

[FRENCHBLUE72]

Just checkin in to see if you got it out?

[allchevy58]

NAPA sells the tool to remove it and then bought a nipple and run rubber hose.

[lil hoodlum]

Oh boy! I wanted to thank everyone for their input and advice!

I haven't worked on it yet. I bought an 1/2 inch easy out but have decided to use a heater hose coupler remover like the one that Rooster's 67 posted. I thought I would be working on this Christmas day but was enjoying the day instead.

Hopefully tomorrow will be the day that I can get this project done! My girlfriend is currently using her step dads truck. He is out of town but will be back in the next few days so it's got to get fixed before then.

I would like to get my girl to make a video of me fixin' it so that I can post it here for anyone else who may run into the same problem as us.

I laugh about it now, about how I was going to "fix" it with some copper tubing and J.B. Weld. Everyone who has posted has encouraged me to repair it correctly the first time. I am sure my planned "repair" would have failed at the worst time.

Again thank you everyone for the advice! It is very much appreciated!

Keith

[lil hoodlum]

Well I finally had a day off from work so I decided to get this truck fixed and back on the road. I went ahead and purchased a heater hose coupler remover tool made by Lisle at O'reilys. Was like $6.

I ponded it in, didn't have to pound it to hard because the metal was pretty soft. I squirted some penatrant to aid in the loosening up. I attached my ratchet on the coupler remover with a 5/8" socket and gave it a couple turns. I instantly knew that the metal was too soft and the coupler remover wasn't going to work.

So I just got to it with a screwdriver and hammer. The metal bent so easily and actually got 2 good size portions cleared out of the way. The left over fitting opening was too large for my tap and die set.

So I headed back to O'reilys to find the correct size tap. Unfornutely they didn't have one that size. I ended up using a hook and pick set to scrape the remants out of the threads. I tightened up the fitting hard but not too hard to strip the threads. Then I took the fitting off and would pick some more of the old coupler out of the threads. It took me a little over an hour to get most of it out. I called it good enough for government work and wrapped some teflon tape around the new fitting and snugged it down. I also replaced both of the heater hoses while I was at it. I bought a new heater core but unforunetly I got confused and told them it was without A/C. My girls truck has A/C, mine doesn't.

Well so anyways I will replace the heater core with the correct one and also replace her thermostat and radiator hoses next.

I got everything put back together and her truck is back on the road. I just wished it wouldn't have taken me 2 weeks to get this thing fixed.

Again, I want to thank everyone for their input and advice!

Keith

[lil hoodlum]

more pics.

Keith

[mcbassin]

Way to go Buddy! I told you could do it. It looks like an EZ-out would have done you no good either. I'm glad you got her fixed up right.

[alsriv2]

Originally Posted by mcbassin

Man, I would get an ez-out that fits the hole closely. Heat it up the intake around the fitting with a hair dryer or a heat shrink type heat gun. Then just try easing the left over fitting out.

If that doesn't work you can stuff a small rag inside the fitting then cut through the fitting with a die grinder on both sides being careful not to get shaving inside the manifold (that's what the rag is for). Be careful not to cut throught the threads. Then just break the fitting in two pieces and unscrew what's left.
I have done a ton of these kind of repairs. If you have time to wait I will send you an ez out.

You don't need to take the manifold off to get that thing out. Or take it to a machine shop.

Use one of these once you get it out.

I have performed this exact repair just like mcbassin describes using the dremel tool. You could also use a small round hand file to "cut" in two small reliefs in the old pot metal. The relief cuts will reduce the pressure caused by the corroded pot metal swelling. Done carefully, you might not have to run a tap into the manifold if the corrosion isnt too bad.

Just saw I posted to late! Congrats on the successful repair!

Al
'69 GMC 2500 Custom Camper
'69 Chevy C10 396BB

[BurnoutNova]

Originally Posted by Maxxd07

Anybody that works on these for a living has a special tool that removes the broken piece with ease. Maybe you have a friend or a old classmate or someone you know that is a mechanic or works at the local chevy garage that could loan you the tool? It has some strait groves in it that are sharp and tapered. You beat it in with a hammer like an easy out but it works 10 times better. The replacements are better but I still consider it a serviceable item, like when the coolant is changed replace it. Keeps the head pains at ease.

http://buy1.snapon.com/catalog/item....re&dir=catalog

I use one of these, works pretty good most of the time.