Broken upper bypass fitting - GM Forum - Buick, Cadillac, Chev, Olds, GMC & Pontiac chat
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1992-1999 Series I L27 (1992-1994 SE,SLE, SSE) & Series II L36 (1995-1999 SE, SSE, SLE) and common problems for the Series I and II L67 (all supercharged models 92-99) Including Olds 88's, Olds LSS's and Buick Lesabres Please use General Chat for non-mechanical issues, and Performance and Brainstorming for improvements.

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Old 05-31-2004, 10:14 PM   #1
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Default Broken upper bypass fitting

Hi Everone,
1994 Bonneville SE N/A. I have found a tremendous amount of usefull information in this forum that has been of great help to me in maintaining my own pontiac so I wanted to pass on a little bit of my experienceI so that mabey it might save a little bit of headach time for someone else. I have had the plastic fitting for the upper bypass hose also break flush at the manifold this weekend. After removing the Altenator out of the way, I first drove a 5/8 inch wood boring bit,( the kind that is flat at the buisness end with a short starting tip in the center of the blade and the shank is a hex(six sided) end that goes into the chuck of a drill), I drove it as much into dead center as i could which did take some amount of paitience as there isn't much room to swing a small tapping hammer(ballpeen) and with nothing solid in the center for the tip of the blade to grab into i did have a few false starts as the blade would drift off center easlily. When i was satisfied it was driven in about an inch or so and centered, i used some vice grips on the shaft and a hammer to tap the bit back out. I then used a 3/4 inch wood bit and drove it in the path that the 5/8 blade had made for me in the center of the fitting. This took a little more effort and time but once it was in place I was able to put an 8mm? six point socket, 1/4 inch drive, and a 1/4 drive breaker bar on the hex end of the shank and reversed(unscrewed) the plastic piece out of the manifold. It did protest and I didn't rush it but it did come out in one piece with just a couple of small palstic pieces inside back behind the manifold threads that did come out when I put my three horse shop vac hose up to the opening and made as tight as seal as iI could. I am hoping this may help some one else. II did replace the fitting with a metal one from Autozone.
Thaks again for a great forum.
Yours in Christ,
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Old 06-01-2004, 12:42 AM   #2
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Wow! I wish you worked at the shop that did my LeSabre when mine broke. Took them 2 days and about 400 bucks for the same procedure.... (And I have all those tools in my garage)

Good thinking!!
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Old 06-01-2004, 12:47 AM   #3
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Heh, I've heard of that being done without good results... Nice work to pull it off.
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