Removing GM Intake Manifold Heater Hose Outlet Nipple

An easy-out may work, but it will probably crumble the remaining nipple into pieces. Obviously pieces of metal in the intake manifold would be bad, but if they were tiny (dust-like) they shouldn't cause any real problems. It's certainly the lesser of two evils to have a little metal dust in the intake verses the crankcase.

Whatever you do, chase the threads when done with a pipe tap. It's either 3/8" or 1/2" NPT thread.

Toyota MDT in MO

I cut two slots partially thru the threads with a stub of a hacksaw blade, the remainder can be dug out with an awl or ice pick. A shop vac can be used to suck up the debris.

It doesn't look like there is enough metal in there to cut any slot in. Maybe I am to the awl point now. This dumb design is shaking my solid allegience to Chevrolet engineering : )

I'd rather walk.

Your wish may just be granted! :)

nate

I'll second Neil's way of doing it. That's the way I get all of these broken nipples out of the manifold. I make 4 cuts, but that's just personal preference.

Ian

Ok, I am not sure I understand. I have a threaded hole in the manifold that has a hollow soft metal tube threaded into it. Are you guys sawing down into the hole to divide the tube into pieces, or are you sawing across the top to create a "screwdriver" slot into the tube? That second one can't work, not enough metal. The first one seems risky to the steel threads of the manifold.

It is risky, but if you are careful, the score will allow a chisel to snap the tube.

Mike

" snipped-for-privacy@yahoo.com" wrote:

As other posters have suggested, sawing into the remaining nipple, try just ONE slot for starters. And use only pulling strokes with the hacksaw blade so as to minimize filings going into the manifold. Once this slot is cut, use of a punch or awl to peel the remainder out. Often just one slot is sufficient and one scored slot partially thru the manifold threads can easily make a fluid-tight connection, using proper dope when assembling. If the filings-into-manifold concern you so much, you could insert a small rag(or piece of one), with a strong cord attached around a corner for later removal. Holding it firmly against the bottom of the hole, you can carefully remove it, along with many of the filings, when the sawing is completed. Other tips often helpful: grind a single, fine-thread blade, so as to make it narrow enough to allow cutting strokes inside that hole. For a handle, wrap a shop rag around the upper end to make a comfortable, safe handle. HTH & good luck, s

Just for reference, I have a 96 1/2 ton with 5.7 and had the same problem. I was successful with the easyhout.

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