heater quick connect broke
You take a hacksaw blade, flie down one end so that you can saw the fitting into 3 pieces and pry the pieces out. try to svae as much thread on the intake as you can.
If you start the truck for a second it will pump coolant out of the intake pipe so that debris doesnt gp to the heater core.
A GM MAster tech told me about teh Vortec LAST resort hacksaw blade idea. It worked.
just buy a regular old brass or metal nipple and use a conventional hose clamp and heater hose. The quick disconnect is there simply to speed up the vehcile assembly process on theassembly line. I leared my lesson years ago. dont reinstall a stock quick/disconnect.
I too suffered from this heater fitting. I'm not sure the welder trick will work, my fitting seemed to be aluminum or some sort of cheap pot metal (I could be wrong on that). Torching and spiral extractors did nothing. I ended up buying at tap and die ($60 for the pair! Ace Hardware has these but $$$$!) I think it was a 1/2-NPT, and I used a 5/8 Drill Bit. 5/8 is smaller than the required 45/64 drill bit, but nobody stocks these. The 5/8 is approx 1/16 too small but it will work because this fitting drills easily and taps easily, remember its a cheap metal fitting. Tap SLOWLY and I did 5/4 turns in for every 1 turn out. (A quarter turn at a time.) Load the drill bit and tap with heavy grease so the shaving don't go into the engine. Also, dont bother with the quick connect (ditto Pauly). buy some 3/4 heater hose, and a tall 1/2NPT to 3/4s hose barb from the HELP aisle. Test the fitting constantly as your tapping because if you tap too deep with NPT, the taper causes the hole to get too large and nothing will seal or torque down. This wasn't really as hard as it sounds but patiences is a HUGE part of making this a proper and painless repair. If you've never tapped threads before, get someone who has, or buy something to practice on. -McKenzie
I just broke the coolant connector on my 1993 5.7L; it broke off flush with the intake manifold. Mine has 180,000 miles and the remainder of the connector just crumbled when I tried to use an EZ-out and an inside pipe wrench. A great source for the required tap is www.wttool.com
(Wholesale Tools). Get the OSG 1/2"-14 NPT pipe tap (made in Mexico but a nice HSS piece with oxide coating) for $14.25. You will need a 45/64" drill bit and they have those with a 1/2" shank for $5.64. I live in Tampa and they have a store here but they have stores all over the US so they can ship quick if they don't have a store close to where you live. They also have a US made tap for about $26 but whatever you do, DO NOT use a high carbon steel tap. If it breaks off in the connector you will have one hell of a time trying to drill it out. FWIW, I looked at the Vermont American taps (Home Depot, Ace, etc) and they are high carbon steel (and they cost over $20). They might just work but why take the chance!