jpmcnam

I have a 1997 c1500 with a 305 v8. For the last year or so the heater hose coming out of the intake manifold has had a slight leak. So slight that it really hasn't affected the coolant level. I've asked the dealer about replacing the hose and they told me that it may be a big job as the fitting going into the intake manifild may break when they try to remove it. If this happens, they will have to remove th intake manifold. I am willing to replace the hose/fitting myself, just wondering if anyone else had run into this and if the fitting broke when the replacement was done. I'd like to replace it before this small leak turns into a big one. Thanks, Jim

sherman69

The fitting on my 97 5.7 was leakiing, so I bought a new one. The parts guy told me it might break when I remove it. Seems the threads corrode Which is why mine was leaking apparently.
He also said it is a pipe thread so if it does break, an easy out and tap from the hardware store should help.
I found out my dealer also had the tap for loan.
Turned out I didn't need it. I tightened a little bit to break it loose then turned it a little at a time back and forth while removing it.
The new one had a sealant on the threads already.

BTW, is it the hose or the disconnect leaking? There is an O ring inside the junction that can leak.

Good luck,
Bob B

MyTOY

Mine Broke on my 97 5.0 while removing as many do.
There is a steel replacement for the crap metal that
was there. I've heard to be careful of using
some thread sealers that can foul sensors in the manifold.

70camaro

Mine broke on my 97 5.7 but I had the manifold off already, then used an easy-out and cracked the boss. MAN was I PISSED!! Ended up drilling it out and haveing the boss welded. Be careful!

nascarmechanic

Dorman part number is 800-401 there is no o-ring in it, just a plastic junction that locks the metal heather hose in.

jpmcnam

Thanks for all the info. The leak appears to be where the metal elbow meets to fitting as opposed to where the fitting meets the manifold.

sak22

This has been a problem on these trucks for a long time. GM opted to go with a softer core metal fitting that would shrink and expand with the heating and cooling of the engine for a better seal vs. the strength and durability of a stainless steel fitting. I just experienced this problem on my 89 and ended up replacing the entire intake manifold. On earlier model trucks like mine, the heater inlet hose was at the back of the manifold vs the front which makes things just a bit more dificult. I guess it's okay though... got almost 17 years out of that heater hose before it broke off in the manifold and to boot, I got a brand new Edelbrock intake manifold. You've got two options... take the hose off yourself at the quick connction then at the other end where it goes into the firewall. Install a new hose (would recommend getting this part at the dealer.. $40) and your done. Or... do the above and very carefully try and unscrew the fitting from the manifold. Install a new stainless steel fitting (also reccomend getting at the dealer.. $8) and connect your new hose. This option might save you alot of money in the long run! FYI... the job I did on my truck ran about $500 between the intake mainfold, heater hose, egr valve, various RTV Sealants and thread lockers. Hope this helps.

sak22

As one of the previous threads stated... make sure that any sealants or thread lockers you use say they are "safe for sensors."