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97 GMC Z71 radiator hose broke off in manifold

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New User

Aug 25, 2005, 4:07 PM

Post #1 of 7 (6980 views)
post icon 97 GMC Z71 radiator hose broke off in manifold Sign In

I hope someone can help me:

I have a 1997 Gmc Z71 Sierra pick up. The connector broke off on my radiator hose from the heater box back to the manifold. The bottom 2/3 of the threads are broken off. Does anyone know how I can remove from my manifld the threads from the broken connector? I can post pictures if need be.

thanks a bunch


Veteran / Moderator
DanD profile image

Aug 26, 2005, 4:08 AM

Post #2 of 7 (6968 views)
Re: 97 GMC Z71 radiator hose broke off in manifold Sign In

I think I know what you mean but the picture would be nice.
I’ve used a large easy-out before but if that doesn’t work, you may need to get in there with a small hacksaw blade. Make three equally spaced cuts in what is left of the inside of the spigot and then collapse it into itself, you should then be able to remove the cut pieces.
The small cuts that are left in the threads of the manifold can be sealed with silicone as the new spigot is threaded in. Only cut as deep as need be to collapse the spigot.

Canadian "EH"

New User

Aug 26, 2005, 5:03 AM

Post #3 of 7 (6963 views)
Re: 97 GMC Z71 radiator hose broke off in manifold Sign In

Alright we are on the same page. I thought I would try to collapse the broken off threading (about 3/4 of an inch of threads from the 1" diameter fitting) that are stuck in the manifold. I wanted to post here before doing anything to see what ideas I got.

I have never used an easy out tool. I thought that they were to remove bolts etc. I did not realize that they might work for a hollow threaded break off such as this. I have the new fitting so I am first going to see if I can find an easy out that would work to remove it.

If that fails I am going to collapse the threads in and remove them as suggested. When I am cutting with the hacksaw do i need to be concerned about the shavings? I could position a shop vac hose over the area if that is a good idea, or is it not a problem if some of the shavings fall down into the manifold?

Do I need a specific type of silicon that is heat sensative to seal the new fitting into the manifold? That seems like a much better idea than what I had which was to use teflon tape.

I have attached a picture of the new fitting. As I stated about 3/4" of the threads are broken off inside the manifold. The break is flush too. The metal is actully crumbly where it broke. The part left in the manifold seems to be less brittle though.

Thanks again for any and all help.

I'll follow up with a progress report.


Attachments: attachment icon MVC-274F.JPG (66.1 KB)

Veteran / Moderator
DanD profile image

Aug 26, 2005, 2:37 PM

Post #4 of 7 (6955 views)
Re: 97 GMC Z71 radiator hose broke off in manifold Sign In

 Well it sounds like you are going in the right direction so keep me informed, I would like to know how you make out with this.
As far as the shavings, don’t worry about them there won’t be all that much and it’s the cooling system that isn’t all that fussy about a “little” crud floating around. (Notice the quote around a little)
The silicone to use is just any form of automotive style, not what you would use on your house windows. LOL
The only other thing I want to warn you about is the threads are pipe threads, they start out shallow and get bigger towards the hex, so be careful when you tighten in the new spigot not to break it off..
Like I said please let me know how the job works out, I hope it goes well.

Canadian "EH"

New User

Aug 27, 2005, 5:20 PM

Post #5 of 7 (6943 views)
Re: 97 GMC Z71 radiator hose broke off in manifold Sign In

I think that I am in the clear.

Here is what happened.

I first called Adavanced auto parts and they said that the hose was a dealer part and I'd need to call the dealership.

I called the dealership and they said they had to order the hose (which was actually fine) but had the connector. I was able to pick them up Friday.

I asked some friends at work and another suggestion was to try to get a diamond punch to bite on the inside lip of the threads and get er spinning out that way. I thought this sounded like a good idea to try before using the hacksaw blade.

I called all around trying to find a diamond punch bit nobody in town had one. I called back over to Advanced Auto Parts and got someone on the line who new 2 whits about my problem. He said he had a prick punch which I might be a ble to use. Also suggested a liquid teflon thread sealer to seal the fitting. He also had for me a solid steel fitting that was much beter than the aluminum piece of crap the dealership sold me. Almost 10$ less expensive too!

I tried the punch but it was hopeless. I had a cheapo chisel that i bought 2 for 1$ at the dollar store for just some purpose as to mangle on a project like this. It seemed to wedge perfevtly down inside the opening. I managed to get the tang loose from the handle and proceeded to chuck the tang of the chisel into my brace and bit.

I torqued down that brace real good onto the chisel. It was set firm up inside the broken off stump off the old fitting. I huffed and i puffed but i could not get that sucker to budge. I sprayed in some more solvent and walked away. Let it soak real good. Went to pick the wife up from work (since i had her car all day) came home and drank a beer. Anyway i got back too it and the chisel broke free.

I took to the hack saw. I cut through in 2 spots. Pried out the first piece , then cut the 3rd slot and removed the last two pieces of threading. I wedged the shop vac hose over the area where i worked to make sure no debris fell in the manifold. Sombody warned that a chunk of that threading could cause a blockage, so i took care to see that all sections of the threading were removed by hand.

I coated the bottom 1/4 inch of the fitting with the thread sealer. It was a bear to get threaded. All i have to use is a cresent wrench. I am gonn see if a friend has a socket big enough to fit over it to get it threaded further (if he feels it needs to be).

I have driven the truck and the temp seems fine and the fitting seems to be holding as well as the seal. Can anyone think of anything else i need to check? I'll try to folow up with a pic of the new fitting in place.

thanks again for the help Dan,

now I can get back to my woodworking. If you have any carpentry questions i am there for ya' Smile


Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

Sep 1, 2005, 9:08 AM

Post #6 of 7 (6874 views)
Re: 97 GMC Z71 radiator hose broke off in manifold Sign In

Great post even if a long read. That silly thing that puts the heater hose into the manifold is a pest. Like Dan said a few bits of junk in the cooling system shouldn't be a problem. It's aweful sometimes that one stupid thing can cost your whole day or more! It happens, Keep your hair and your marriage!Smile


Sep 2, 2005, 10:33 PM

Post #7 of 7 (6860 views)
Re: 97 GMC Z71 radiator hose broke off in manifold Sign In

In Reply To
...and drank a beer.

Some day I'm gonna write a detailed essay on the impact Budweiser and Miller has had on the auto repair trade. Cool

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