Question about 1995-1997 Chevy 1500 Truck Ignition Starter Alarm Switch

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The fitting at the rear of the intake manifold is broken off buy the tool to get it out but not happening

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Posted on Jan 02, 2017

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SOURCE: broken hose connection on intake manifold

This is a ugly thing that happens all the time at my shop. The best way to repair this is to drill the material out and retap the hole . you will need a 1/2 pipe tap, they have them at home depot or your local hardware store . on the pipe tap it tell you what size of drill bit to use . the material in the hole is aluminum and it drills out E-Z. I have also tried to use a small chisle to break out the broken peice out you can do it but you will learn alot of new bad words.The biggest problem is sometimes because of space restriction you have to use a angle drill and a shortend brill bit to even get in the space to drill.Well so far I hav'nt gave you an E-Z way to fix this SORRY. This one is not a very easy one . I hope this helped

Posted on Aug 16, 2008


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If you mean one of the plastic "nipples" that are part of the plastic intake manifold, you can buy a repair kit at your local dealer that is a new metal fitting that will thread into the plastic intake manifold.

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intake manifold gasket. when it leaks water will enter a cylinder causing the sprark plug to short out. when the engine gets hot enough the water will cook off in the cylinder allowing spark to take place. 80% chance intake manifold gasket, buy the upgraded part. 20% chance head gasket. Take the intake off and check for broken intake manifold gasket then buy parts.

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Distributorless Ignition System chry-02-33-786.gif
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Heater hose connection that fits into rear of intake manifold "disintegrated" leaving parts of it behind. How do I get it out without removing the manifold? Truck is a 1993 GMC Sierra 1500 5.7 engine...

I see this problem fairly often and you can get the fitting out but you need a bit of patience to do so. I remove probably 6 of these a year and how I get it out is to take a new, very sharp, hacksaw blade [just by itself] and very carefully using the blade by hand cut a 2 or 3 equally spaced vertical grooves through the fitting. The fitting is a fairly soft pewter like metal and cuts fairly easily just the same you want to just cut through the fitting until you are just up to the threads in the intake and not beyond. Once you have these grooves cut you can take a very sharp pointed chisel or center punch and with a small hammer you can catch the edge of the fitting and and tap & peel it away from the manifold piece by piece to remove it. I've tried several specially made "easy outs" to remove these but the problem is that the fitting is stuck so hard to the intake that it just will never turn out again. I replace these failure prone fittings with a simple hose barb type brass or steel fitting and then replace the heater hose with a new piece of plain hose. A really tough broken fitting may take me a half our or so to remove but expect to spend a couple of hours on your first one. Good luck!

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1 Answer

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I'm really not sure what you're asking. There is no gasket in the intake valve. Now, if you are talking about the intake manifold gasket at the heads, you need to look at the plates that are on the intake manifold themselves.

There is a plate on each runner of the intake. These plates are marked with a "R" for Rear and a "F" for Front. One side of them is flat with the other side having a "counterbore". The "counterbore" goes towards the head with the gasket sliding up on the manifold so that it's shape fits up into the counterbore. When the plates are tighened down, they flatten out the gaskets and form a seal against the head and the manifold.

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