Old glowplug controller snapped off in crossover...

[Mike82ndABN]

I have a TSU that I was about to install today. When I went to remove the old glow plug controller, I found that it was overtorqued or seized into the crossover pipe.

I went at it gently with a ratchet and big socket, couldn't move it, then put a breaker bar on the socket and slowly applied more pressure. The old glow plug controller snapped off pretty flush with the pipe.

I've gone ahead and added more PB blaster and will let it sit overnight.

What is my best course of action at this point? Try to use an extractor somehow, or use a screwdriver/chisel/mallet to attempt to rotate the stuck part until it backs out?

Looks like someone used teflon tape on the threads.

Should i just remove the crossover and attack it from inside? I am worried if it shatters I will have pieces fall into the cooling system.

 

[DatGuyC]

I'd probably remove the crossover and try to get it out, then the worst possible thing that could happen is you have to buy a new crossover which isn't expensive. Maybe try a large easy out that they use on bolts when they shear off?

 

[86humv]

I have cross overs if yours ends up bad.

 

[Retiredwarhorses]

Probably a good idea to just remove it and replace the crossover....those threads can easily become buggered up and
will fail or become a leak point. Easy to replace...you will need 2 gaskets for the crossover and 1 for the the thermostat.

 

[Mike82ndABN]

I ended up removing the crossover. The broken piece was completed seized so i used heat and an extractor, no luck. I knocked what i could out with a chisel, then took a big drill bit to it.

Once i got the broken piece cut down to the beginning of the threads, I was still unable to get the material out from between the threads, it was permanently bonded to it.

I did notice that there seems to be a thread insert inside the crossover, perhaps it's a helicoil in there, is this normal? Maybe someone stripped it before and they repaired it with the insert. Whatever it is, it is shiny steel looking. I can't get the old material out from between the threads so at this point I will be yanking out the helicoil and seeing if I can replace it, or just spending some cash on a crossover.

Is it normal for there to be a helicoil type insert in there?

 

[DatGuyC]

Don't remember seeing one in my crossover but I'm not 100% on that

 

[86humv]

The takeoff 6.2 I have has a helicoil along with a bunch of 6.5 crossovers.

 

[Retiredwarhorses]

I ended up removing the crossover. The broken piece was completed seized so i used heat and an extractor, no luck. I knocked what i could out with a chisel, then took a big drill bit to it.

Once i got the broken piece cut down to the beginning of the threads, I was still unable to get the material out from between the threads, it was permanently bonded to it.

I did notice that there seems to be a thread insert inside the crossover, perhaps it's a helicoil in there, is this normal? Maybe someone stripped it before and they repaired it with the insert. Whatever it is, it is shiny steel looking. I can't get the old material out from between the threads so at this point I will be yanking out the helicoil and seeing if I can replace it, or just spending some cash on a crossover.

Is it normal for there to be a helicoil type insert in there?

yes on the helicoil....

 

[KansasBobcat]

What size wrench fits the old GPC? My 1 1/8 1s too small. My 1 1/2 seems too big on the new sensor. Are these metric? Soaking old GPC threads with Kroil and hope it doesn"t break!

 

[Retiredwarhorses]

I just use a large crescent wrench...it's pipe thread,no don't over torque it, use a thread sealant.

 

[KansasBobcat]

I just use a large crescent wrench...it's pipe thread,no don't over torque it, use a thread sealant.

Thank you for prompt reply. I will use crescent. Is pipe sealant OK?

 

[Retiredwarhorses]

I use permatex thread sealant...high temp, it's white

 

[KansasBobcat]

What size wrench fits the old GPC? My 1 1/8 1s too small. My 1 1/2 seems too big on the new sensor. Are these metric? Soaking old GPC threads with Kroil and hope it doesn"t break!

After soaking junction with Kroil GPC came loose with minimal effort. No evidence of helicoil in cross-over threads.