Intake coolant fitting

I am replacing the intake gaskets on a 92 c1500 350. I have the intake out but the coolant fitting that goes into the back of the intake broke on me. It looks like metal but breaks like plastic. Any 1 have any tips to get it out of there. It broke off flush with the intake so i cant grip it with anything the only thing left are the threads. I tried hammering a big screwdriver in there and turning it but it didnt work. All i can think of now is to chisel it out and try not to mess up the threads. Any suggestions from ppl who have had this problem would be greatly appreciated.

I am replacing the intake gaskets on a 92 c1500 350. I have the intake out but the coolant fitting that goes into the back of the intake broke on me. It looks like metal but breaks like plastic. Any 1 have any tips to get it out of there. It broke off flush with the intake so i cant grip it with anything the only thing left are the threads. I tried hammering a big screwdriver in there and turning it but it didnt work. All i can think of now is to chisel it out and try not to mess up the threads. Any suggestions from ppl who have had this problem would be greatly appreciated.

common problem with these. using a hack saw blade , with no frame , cut into the fitting , then when you have a good cut almost thru from end to end use a screw driver and gently collapse the fitting ..then with needle nose pliers unscrew..

use teflon tape when installing a new fitting. cutting into the manifold threads slightly will not hurt it ..but usually cutting that much is not necessary.......

My local tool store sells a kit just for this- it has the big easy out, a pipe thread tap, and a new hose adapter- all for about $25. Works great.

Very, very common problem.

The original fittings were made from zinc, and end up corroding badly...two of them, one in front and one in back to serve the heater core. Dorman makes steel replacements if you want to stay OEM pipe connections...test them with a magnet to be sure they are steel. Others will find a plain hose fitting adapter, screw it into the manifold, cut the quick-connect ends of the hoses off, and band-clamp them. Either way works.

I would be careful hammering at the piece remaining because any big pieces that break off go into the manifold and may not get flushed out. As suggested, you can saw part way into the piece through the hole in two opposite places. Then tap a screwdriver at the midpoint between the cuts to make it collapse on itself. Once you get it out, flush it thouroughly with water to get rid of the shavings.

Good luck!

I ended up using a hacksaw blade and a screwdriver to chisel it out. I had to cut it in 3 spots to get it out. It was so corroded it looked like it was welded to it. Now i just have to get it all cleaned up so i can put it back on. .I didnt even tear up the threads and thats what i was worried about. Thanks for the tips.:)

I ended up using a hacksaw blade and a screwdriver to chisel it out. I had to cut it in 3 spots to get it out. It was so corroded it looked like it was welded to it. Now i just have to get it all cleaned up so i can put it back on. .I didnt even tear up the threads and thats what i was worried about. Thanks for the tips.:)

I have a lot of experience removing fasteners and fittings that have corroded themselves in place...

very small to very large in size. using an easy out on a corroded pipe fitting will just expand the metal fitting an bind it up more...cuting the fitting and shrinking its dia you can then remove it...


when its safe to do so using a good torch properly adjusted and sized you can remove most hardware siezed up...

as with most threads like you have here a round pipe wire brush will clean up the debris/corroded mess then using pipe tape re install new part.... good luck !

I have a lot of experience removing fasteners and fittings that have corroded themselves in place...

very small to very large in size. using an easy out on a corroded pipe fitting will just expand the metal fitting an bind it up more...cuting the fitting and shrinking its dia you can then remove it...


when its safe to do so using a good torch properly adjusted and sized you can remove most hardware siezed up...

as with most threads like you have here a round pipe wire brush will clean up the debris/corroded mess then using pipe tape re install new part.... good luck !

My original plan was to heat it up but turns out my propane leaked all out so i went to plan B.