Any ideas? Snapped Heater Hose adaptor...SOLVED

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TS2304

TS2304

Active Member
Posts
145
Location
Aylesbury
Hello -
Was sorting out my heater box on my s3 today and have hit a problem...
Went to remove the adaptor that joins the heater pipe to the cylinder head (part 624091 )when instead of unbolting the bugger just snapped off!
So now I'm left with part of the adaptor still threaded into the head and the other in my hand.
Attached photos of the place where it fits as well as the remaining part so you can see what I mean.
The question is, before i try and figure out some dodgy way of getting on, has anyone got any bright ideas how best to remove the remnants so I can get hold of a new part and screw it in?
Or better still, had the same issue and solved it? (tho' i'm guessing others aren't as stupid as me to find themselves in this position!)
Any ideas? Thanks
Fitting.JPG fitting close up.JPG pipe adaptor - broken.JPG
 
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Thin sharp chisel and hit it a few times to get the remains moving. If that fails it'll be a combination of drill/chiselling the remains out. At least its a relatively soft metal. Of course access is limited, maybe remove rocker cover to make more room?
I don't see a copper sealing washer. Has a PO maybe used threadlock on it and that's why it broke?
 
See if you've got a torx bit (or similar) just big enough to tap into the bit that's left in the head and try unscrewing that way.
 
If you have torx bolt set [ male ] tap in one with splines a bit bigger than the hole so it grips. A cooking with a blowtorch will help free it.
Woody got there first.:cool:
 
Cheers gents, should have a torx to fit so I'll give that a go tomorrow - will let you know how i get on.
@nathanglasgow, there was no washer and the pipe just snapped off at the lightest of touches so i'm thinking something was done previously - hopefully he didn't weld it in there!
Next problem is to try and find some way of getting the replacement part over the bank holiday so I can get it running again for work on Tuesday (Why do these things always happen on a bank holiday?!?). :mad::mad:
 
Hi It may have been overtightened and damaged before, Put some penetrating oil or plusgas on tonight and let it soak all night. I would try with a thread/screw extractor if you can get one large enough (this will work without hitting the cylinder head) but warm the area up with a bow lamp prior to trying, to warm up and soften the seal. Also have a look at screwfix part number 6089R its a 15mm tail to 3/8bsp adaptor but bear in mind your part might be 3/8bsf. But its only £4.00 ish for 2 pack
 
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I would have a go with a junior hacksaw blade and cut through or almost through the threaded sleeve at two places then use a small punch to drift the brass bit into the hole
 
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I would put a greased bit of rag in the bottom and very carefully drill it the tapping drill size for the thread. Get it right and you can pick the thread out with a scriber..
 
I might try and find a piece of brass/ally rod that is a nice snug fit in the hole, then drill down between the rdd and the brass thread on opposite sides until you can see the threads, then remove the rod and lightly chisel out the two halves of remaining thread?
 
Thanks all - managed to get it fixed. Used the torx idea with a bit of heat first and the old adaptor thread came out a treat, no problem. Then a quick trip to B&Q and got hold of a 12-15mm coupler which has the same external thread dimensions.
IMG_3430.JPG
attached a short length of copper pipe to the 15mm end, screwed it into the head and slipped the hose over the top and clamped it.
IMG_3431.JPG
Just ran the engine for about an hour to check it under heat and so far so good - no leaks and heater still works (as much as it ever does on the s3 anyway...).
It'll do til i can get hold of the proper adaptor anyway. Thanks all for the advice.
 
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