Removing Plenum Pressed Fit Fittings the Easy Way

[Dynomite]

The removal of a Plenum Pressed In Fitting came up recently. One would want to remove the Pressed In Fittings if they are leaking or if you want to plug the port with a 1/8 inch NPT Aluminum Allen Head plug.

Uauallly the only way I am able to get such out including the coolant manifold bolts sometimes is to use a torch with a little heat. A reason not to use heat in some cases...it disturbes the original coating.

But you cannot use heat successfully if you do not have much left to grab with vice grips. You could drill but you have to be VEEERRY careful so as not to upset the base hole that is Aluminum....

1. First try vice grips and after you destroyed anything you can grab on to (if that is the case)....
2. use an Easy Out. Then after that does not work (if that is the case)....
3. Use an Easy Out inserted in the pipe with vice grips tight on outside and slowly wiggle (rotation) clockwise/counterclockwise many times untill the fitting loosens. If that does not work.....(The Drill Method has very recently worked perfectly for two of us independently.)

4. use a drill as follows.......
a. I would start out with drill bit that just fits inside the original tube.
b. Drill the length of that pressed in insert (the fitting I sent you should be clear on length of inserted part).
c. Go one size drill bit up and drill again....1/64 inch increments
d. Keep doing that untill the last pieces of the pressed in fitting come out which last drill bit should be less than hole diameter in the Aluminum.
e. Again....only go as deep as that new fitting indicates. This after you have exhausted all techniques of pulling with vice grips and easy out.
f. If you can get the drill bits in 1/64 inch increments the better. You have to keep the drill bit straight somehow.

5. Practice with the drill as having a very light trigger finger able to stop the drill and KEEP the drill bit just barely turning is key. Secondly...keeping that drill bit straight with the fitting without a drill press is also key.

JB Weld around the pressed in part of the fitting you will insert to correct any screw ups during drilling. If you get the fitting out without any damage to the hole in Aluminum, just use some Red Loctite around the fitting before inserting.

Removing a Pressed In Fitting

See also Removing Cam Cover Bolts the Hard Way