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Heater install...stuck intake manifold plug


jfw432

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I've got the majority of my heater install complete in my 2000 Response LX but the plug on top of the intake manifold is stuck...and I mean stuck big time. First I tried with the engine cold. Then I tried warming up the engine a little to help expand things. I've tried pounding on the plug with the hex wrench installed to help break it free. Finally I used a breaker bar and ended up just rolling the hex wrench inside the plug.

Engine is the Monsoon.

Any ideas?

Edited by jfw432
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If the plug is stripped and the allen wrench will no longer grip, you might need to drill it and use an extractor. Best to attempt to make sure no drillings/shavings go down into the engine by using a magnet while you drill also a little oil tends to make the shavings cling together. Hopefully @oldJeeps idea works so you do not have to go this step! good luck!

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If it is stripped I would weld the thread end of a bolt to the plug and use that to remove it.

Can you weld on that plug? What is the material and that of the intake manifold? Looking for a serious answer.

Thanks

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Can you weld on that plug? What is the material and that of the intake manifold? Looking for a serious answer.

Thanks

I'm guessing it's a steel plug and aluminum intake manifold. I don't have a welder anyway but even if I did, I'd be a little leary of doing it. I can see sparks melting carpet and seats. Not to mention the fuel line is only an inch or two away.

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Can you weld on that plug? What is the material and that of the intake manifold? Looking for a serious answer.

Thanks

I'm assuming steel plug since I've never seen an aluminum one on a production motor.

But if he doesn't have a welder and welding blankets I guess it is a moot point.

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Ok so I used a propane torch around the plug but I don't really know if that helped or not. Since my 3/8" hex socket slipped once, I figured it wasn't going to be much use. So I took a 10mm hex socket, drove it into the plug with a hammer so it would have a nice fresh grip and managed to get it out that way. Took a little work to get the plug off the hex socket but I got it.

Now I've got little to no heat coming out of the heater and looking for ideas on the cause here. http://www.themalibucrew.com/forums/index.php?/topic/57988-just-installed-heater-but-not-getting-any-heat/

Edited by jfw432
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