Hi Fellow 6.5ers,

We are in the middle of have an SOS with pictures of the disaster! :D

We were replacing the intake (upper and lower) and the inlet heater hose broke off where it connects to the thermostat housing. We tried to move the hose just slightly, and it snapped. It appears that the male pipe thread that screws into the thermostat has rotted out. We now have to figure out how to remove the thread left in the thermostat.

How would you remove the threads without damaging the thermostat housing?

Can we eliminate the metal tubing/hose that runs from the thermostat to the heater, and just replace it with rubber heater hose (and possibly route it a little differently)?

We are running out of sunlight! :eek: Suggestions appreciated.
Jon

http://www.dieselplace.com/forum/garage.php?do=big&p=48278

Hi Chi

Got a couple helps for ya...

- you can cut-down a hacksaw blade and use it to cut into the inside of the fitting; cut a few slices in it and then peel out the piece you isolated with a chisel. Careful of the threads.

- you can also try an easy-out, or use a chisel on an angle to try and turn it out.

In both cases, be careful fo the threads, but remember that you can always seal them up with a little RTV later.

Once it's out, follow the directions found here:

http://www.dieselplace.com/forum/showthread.php?t=116217

And remember that this forum does have a search feature... and somebody has almost ALWAYS had the same stuff happen to them before!

Jim

How big a hurry are you in ???

I have a good crossover off my old motor left over just sitting on the shelf. If you dont get that one fixed just cover the shipping and its yours.

Let me know. I can ship it out first thing mon. morning.

Jim and NYCEGUY01: Thank you so much for your help! Jim- the link you sent helped a lot- sorry I didn't see it before on my search. I also had to keep running outside to be sure no one was stealing my tools :cool:, and I see there are threads related to this.

NYCEGUY01- let me try Jim's methods to remove the left over, corroded, pot metal threads. If I totally mess up the crossover housing, then I would be very grateful to take you up on the offer. I'll PM you later today with the outcome either way.

One last question:

It appears that in most cases, people replace the quick disconnect with TD and others' solution: a pipe/barb fitting I got from Lowes (picture below).

Wouldn't it just be easier to replace the entire metal heather hose with rubber heater hose? Would too much flow be a problem?

Thanks again for all your help!

http://www.dieselplace.com/forum/attachment.php?attachmentid=28820&d=1163815777

Lots of guys have replaced the whole thing, but as I recall, there is a restriction in there that protects the heater core from too much flow. I think there is a specific-diameter barb that will put this restriction back for you, but I can't remember which part it is.

I'll have a look around for ya. Keep an eye on your tools!

You can also buy a new part that is JUST LIKE the quick-connect fitting you're taking out, but the replacement part is steel, not magnesium. Costs about $8, and I think NAPA carries it.

Here's the restrictor thread:

http://www.dieselplace.com/forum/showthread.php?t=163034&highlight=heater+hose+barb

Jim

Jim and NYCEGUY01: Thank you so much for your help! Jim- the link you sent helped a lot- sorry I didn't see it before on my search. I also had to keep running outside to be sure no one was stealing my tools :cool:, and I see there are threads related to this.

NYCEGUY01- let me try Jim's methods to remove the left over, corroded, pot metal threads. If I totally mess up the crossover housing, then I would be very grateful to take you up on the offer. I'll PM you later today with the outcome either way.

One last question:

It appears that in most cases, people replace the quick disconnect with TD and others' solution: a pipe/barb fitting I got from Lowes (picture below).

Wouldn't it just be easier to replace the entire metal heather hose with rubber heater hose? Would too much flow be a problem?

Thanks again for all your help!

http://www.dieselplace.com/forum/attachment.php?attachmentid=28820&d=1163815777

That is what I did, in the picture. The same thing happened to me when I changed injectors. Thought wow, it would be a lot easier if I could take that hose off, so here comes the wrench with a little force and snap.:mad:

Before the repower I had replace the metal hoes etc.. with no restrictor and had no ill effects at all. Maybe I got lucky bit I drove it for 15-20k miles like that.

When my quick connect started leaking I had some hose and a fitting allready in the misc parts bin and used them.

My quick connect was leaking and I did the same.

Restrictor is there for a reason....I just replace the quick fitting with another quick fitting....for $15 it is cheap insurance on replacing the heater core...