Any tried and true method of removal?
 

Any of you guys have a tried and true method of removing these vacuum set screw plus from intakes? I obviously tried a screw driver to NO avail and it finally skipped SO I stopped before I mess anything up any further!!!

Thanks!!!

Re: Any tried and true method of removal?
 

I had the same problem with cast iron valve covers. I ended up carefully drilling it out incrementally increasing drill bit diameter until I was afraid of hitting the threads or the bottom seat in the valve cover. Then I used a pick to pry the remaining brass bits out (along with some choice words which are inappropriate to mention here). Obviously I had the valve cover on the bench and not on the engine.

I think the issue of dissimilar metals is the culprit. Looks like you have a harder challenge with soft aluminum.

Re: Any tried and true method of removal?
 

Thanks Dave
The current plan is to remove the intake so I can get a better angle on it and not contaminate anything else and do just as you have described…..I can’t think of any other way!!!

Re: Any tried and true method of removal?
 

If you can get a straight shot at it from the inside, it would be easier to drill it out and the drill might catch and run it right out. Or is this what you meant by a "better angle"?

Re: Any tried and true method of removal?
 

Hand held impact driver? The type you hit with a hammer?

Re: Any tried and true method of removal?
 

I'd start with a drill. Make sure you are as close to the centre as you can get. Put a deep center punch mark on it. Hit it with the center punch maybe 50 times, not too hard. Drill a hole about a 1/4 of the thread size. Try to get as much heat into it as you can with the drill. Try an easy out if you have one, or turn it over and drill it from the inside, with a drill about 1/2 of the diameter of the screw, using slow speed and a fair bit of pressure. If it hasn't come out already Just keep drill slightly bigger holes until you just break though the wall of the screw. Then get a fine punch and gently collapse the remainder into the hole.

Re: Any tried and true method of removal?
 

Heat the area around the plug with a propane torch, DON'T have to get it very hot, lots of expansion to aluminum and pot metals.

Re: Any tried and true method of removal?
 

A combination of Mart and Terry with a shot or two of PB blaster when hot normaly works. The aluminium will exspand much farther and faster then the steel plug. This should break the bond and also alow the oil to get down in the threads. Tim

Re: Any tried and true method of removal?
 

dont the intake have a taper for the fitting? you could end up messing that up by drilling it out

Re: Any tried and true method of removal?
 

Just did one of these two weeks ago. Used my mini-ductor and a shot of free-all and it came right out

Re: Any tried and true method of removal?
 

If you fool around with old Fords regularly, I can't recommend a heat induction tool highly enough. They are a life saver.

Re: Any tried and true method of removal?
 

Tim, I'm always looking for a better tool. What heat tool do you have? Tim

Re: Any tried and true method of removal?
 

Hey Tim,

I got the Bolt Buster brand tool. Mainly because it's made in the USA. Since I got it, the torches only come out for cutting. It's been a life saver for our daily drivers and old Fords.


https://boltbusterinc.com

Re: Any tried and true method of removal?
 

Not tapered.

Re: Any tried and true method of removal?
 

I have to ask . . . what the heck is a "mini-ductor"???

Re: Any tried and true method of removal?
 

Whaa Laaa