i had a similiar situation happen summer of '05 with a truck of an aquantance of mine, and i took the intake manifold off, had the old fitting bored out, then had a new aluminum fitting made and welded on. well, the budget is not there for this customer to do that, so i'm asking now before i go boogering up the intake manifold if anyone has any tricks for getting a coolant fitting out of an aluminum intake manifold when the fitting is corroded and crumbling. i've got the intake off the car so i don't have to fight with it in the back of the engine bay (this is on an 87 lg4)

any suggestions are appreciated.

 

I had the same problem with my '87 caprice, the fitting snapped off right at the intake manifold. I never got the remnants of the fitting out and cracked the manifold trying to use an easy-out (it's just a snow day car and it's sealed up with JB weld for now). If the fitting is corroded and falling apart to the point that you can't wrench it out, the only advice I can give is to try to tap the opening or drill it out and use a heli-coil.

 

A trick that I learned working on motorcycles is heating the area with a propane torch and then dripping wax on it.
Motorcycles don't have coolant fitings tho, but it works on stuck screws.

 

I've used this method too and it really works. Just don't try to remove the offender all-at-once. Use the back-n-forth rotation method of turning the stuck fitting, until it reallys starts to unthread easily.

 

With the intake off you can do repeated doses of PB Blaster on both sides- on top and from underneath directly to the threads. Do this 3 days running, couple times a day then heat the aluminum intake with a propane torch (not the steel fitting) and you'll usually get it out.

 

steel fitting? Look up the electrolysis method. Involves some chemical as well, I forget... It'll dissolve all the steel in the bath, and leave AL un-touched. Nice and hands free method.

 

well, we we're able to drill it out and run a tap through it and it's all good now...

 

i use a hack saw blade to cut 2 slots about a quarter of an inch apart in whats left of the old fitting & then use a small tipped chisel to break it out. it works good, its fast most of the time, it normally takes me about 30 minutes from start to finish with the intake on the motor. the only thing to watch for is don't cut too far into the threads on the intake.

 

maybe someone should have been using deionized water
time is a ticking... spring shoot out sucker! Better be prepared Matt... I am bringing juice.

 

looks like i may have the jug on mine by then...get ready to look at some sportcoupe taillights!!! you bringing the new formula?

 

Yeah, I am bringing the formula... remember loser buys lunch.

Hopefully by then, I will get my 700R4 where it needs to be. It is being stubborn now. Happy thanksgiving BTW. Im off to get fatter!

 

haha, i'm already there bro (the fatter part), happy turkey day to you as well!