Aluminum intake fitting removal?

[Brian K.]

Okay, I've had problems in the past and wanted to know what others do. How's everyone removing the steel heater hose fittings from aluminum intakes without cracking, breaking and stripping the threads out of their intakes? Thanks sincerely Brian

[Joe L.]

Re: Aluminum intake fitting removal?

Okay, I've had problems in the past and wanted to know what others do. How's everyone removing the steel heater hose fittings from aluminum intakes without cracking, breaking and stripping the threads out of their intakes? Thanks sincerely Brian

Brian----

Basically, there are 2 ways to do it for THREADED fittings:

1) Heat the area surrounding the fitting until it's very hot. Then, while it's hot, back the fitting out. This method makes me "nervous" with aluminum, but I've used it to remove ball studs from bellhousings and it's never failed me. Don't use anything hotter than a MAPP gas torch;

2) Drill out the fitting using increasingly larger drill bits until what remains of the fitting is "paper thin". Then, you can usually remove the remnants with a sharp awl or similar tool.

Method number (2) is the one that has to be used for pressed-in fittings (i.e. bypass fitting on many earlier aluminum manifolds).

If the above makes you uncomfortable, take the manifold to a machine shop that has experience in this sort of thing. They will use one of the 2 methods described.

[Page C.]

Re: Aluminum intake fitting removal?

Hi Brian,
This is what works for me. I cut it off, leaving about 1/4 inch beyond the manifold. Then take a hacksaw blade and cut the nipple in 3 or 4 places from the inside to the point it almost is breaking thru to the manifold threads. Then I take a hammer and punch a collapse the nipple. You can then screw it out by hand.
I have never had any luck using heat.
Regards
Page

[Randy R.]

Re: Aluminum intake fitting removal?

My father taught me a method similar to Page's method to remove a nipple. I have used it many times. Saw the nipple in two places about 1/4 inch apart from the inside. Drive the small piece out with a punch by driving it towards the center of the hole. Then put the punch on the edge of the remaining piece of the nipple next to the gap where the small piece was removed. This will bend the piece away from the female threads. You can then thread this piece out. Be careful not to damage the female threads.

Randy

[John D.]

Re: Aluminum intake fitting removal?

Okay, I've had problems in the past and wanted to know what others do. How's everyone removing the steel heater hose fittings from aluminum intakes without cracking, breaking and stripping the threads out of their intakes? Thanks sincerely Brian

Here is how my helper removes the FI intake fittings. He puts the intake or base plate in a big hyd. press. He sandwiches the base plate first between two thick pieces of wood. Then he gets his big torches out and heats around the fitting. Next he uses PB Blaster penetrating oil and douses the fitting with that. Then he walks away until it cools.
Next he goes back and heats up the aluminum again and uses a huge breaker bar and typically the fitting comes out with no damage.
Those 63 to 65, etc. slotted rusty by pass fittings are a pain for sure.
Lots of those get cut out. John D

[Clem Z.]

Re: Aluminum intake fitting removal?

i have found using a impact wrench works better than just pulling on a box end wrench.

[Dennis C.]

Aluminum intake fitting removal?

I agree with Clem's method - impact wrench - as long as the fitting is a straight (not curved) one. Always worked for me.

[John D.]

Re: Aluminum intake fitting removal?

i have found using a impact wrench works better than just pulling on a box end wrench.

Impact wrench Clem is good idea. Except mine just makes lots of noise and stalls out. Not enough guts. I used to pay ASL Company to burn them out. They charged 35.00 each. What is the name of that tool? Three initials. JD

[John D.]

Re: Aluminum intake fitting removal?

I agree with Clem's method - impact wrench - as long as the fitting is a straight (not curved) one. Always worked for me.

I sure would like a nice tool for the water pump by-pass fitting. The big screwdriver slotted one. The sockets I have found are too small. Not wide enough. Any ideas? JD

[Dick W.]

Re: Aluminum intake fitting removal?

Impact wrench Clem is good idea. Except mine just makes lots of noise and stalls out. Not enough guts. I used to pay ASL Company to burn them out. They charged 35.00 each. What is the name of that tool? Three initials. JD

EDM. Electrical Discharge Machining

[John D.]

Re: Aluminum intake fitting removal?

EDM. Electrical Discharge Machining

Thanks very much Dickie. I wish someone in my hood had one of those EDMs.
Maybe Clem knows the answer as he lives near me. I used to get a lot of fittings removed with the EDM method. JD

[Clem Z.]

Re: Aluminum intake fitting removal?

Thanks very much Dickie. I wish someone in my hood had one of those EDMs.
Maybe Clem knows the answer as he lives near me. I used to get a lot of fittings removed with the EDM method. JD

in the old forbes road school building is a large EDM company.

[Bill W.]

Re: Aluminum intake fitting removal?

whats the best way to "fix" the threads on the intake after the fitting pulled most of them out with it ???

[Bert L.]

Re: Aluminum intake fitting removal?

Plumber's internally gripping pipe wrenches have worked well for me on small pipe fittings if they aren't too badly corroded. Visible damage to outer surfaces is minimized.

[Joe L.]

Re: Aluminum intake fitting removal?

whats the best way to "fix" the threads on the intake after the fitting pulled most of them out with it ???

Bill-----


To prevent exactly what you described is reason that I recommend the methods I previously described. However, if thread damage happens, I believe you can get heli-coils for pipe threads. Or, you can weld it up and re-drill and tap.