96 Chev 1500 5.0, was replacing the heater core and the two lines today. When I went to remove the quick disconnect male end that goes into the engine just behind the thermostat it broke off inside... I tried using vice grips to twist what was left and it broke off, so then I used a bolt extractor and it just dug the edges to where I am nervous that I will ruin the threads... So now I have this stupid piece broke off in my engine so thin I can't use a bolt extractor. Does anyone know what I should do now? I am fresh out of ideas besides attempting to tap and die the original threads into it, but then I risk dropping all of that crap into my cooling system.... Help please help!

 

Coat the tap with heavy grease. The grease will trap and hold the metal bits it creates. Go slowly and clean and regrease the tap about every 2 or 3 threads. I had the same thing happen on my 1990 and this process worked well for me. Good luck .\

 

Yeah I just tapped it then made a redneck contraption for my vacuum and sucked out all the crap from inside the intake manifold, anyways I'm actually about to try all the craziness I had to pull to put this aftermarket homemade piece into my truck.