Dipstick tube broken off in block

[terrible one]

  Every time I work on this car I run into a problem. The engine is just about ready to start for the first time and is already in the car. Today I go to install the dipstick assembly and it doesn't fit at all. Come to find out there is an old tube broken off in the port! WTF how did that make it through the machine shop?!

Anyways, it had a good lip on it so I tried to pull it out with the needlenose and no dice. Next, I screwed a bolt just barely larger than the inside diameter of the tube and tried to pull it with that, but still nothing. Finally I drop the pan and tried pushing it out first by hitting the bolt I had screwed in from the bottom, which resulted in the bolt stripping out and coming out of the tube, and then with a flathead screwdriver and a hammer. Nothing happened besides me marring the shit out of it. Finally I attacked it from the top again and tried to cave it into itself by driving the punch into it/ alongside it but it just broke it more.

I'm out of ideas so does anyone else have a suggestion? And if not, does anyone know the size ofthe dipstick hole (383) so that I can drill it out?

[tan top]

should of come out easy ,  with the oil pan off & tap it back the oppsite wey     , had one broke off in a spare block , it came out that way  , but was stiff

[oldrock]

seems like pushing up from underneath would be a snap. Did you try something close to the size of the opening like a dowel rod, pvc pipe or something? Would think something that fits fairly tight and then tap with hammer to force it up so you can get at it with vice grips. Oh and if you have drained it anyway, maybe some penetrating oil around the stuck item since it could have corroded/rusted in place. Got to say that is a new one though.

[jeryst]

Does it move at all, in any direction?

I mean, can you turn it or anything, or is it completely stuck?

[terrible one]

I'm just as mystified by this as you guys! It should have been a sinch! It is obviously the stock one and has been there for 40 years. I have tried pushing it out from the bottom with: flathead, Phillips head, nail punch, and finally a 5mm socket that slid in the port but was a bit too small and wanted to mate with it instead of pushing it out.

It won't move at all; I can't try pushing it down out the bottom of the engine because of the shoulder it has and the limited angle. I'm seriously considering drilling it out. Does anyone know the size of the hole?

[b5blue]

Try an "ez out" or tap it to cut the steel up and weaken it's grip, my new one was a royal pain in the butt to install keep that in mind. 

[R2]

Can you put some heat to it ?? to help work it out ?

[oldrock]

Try an "ez out" or tap it to cut the steel up and weaken it's grip, my new one was a royal pain in the butt to install keep that in mind. 

tap is a good idea. I'd try that if I was you. Just make sure you don't go too large and cut the entire tube out. Maybe thread it in a few turns and see if you can hit the top of the tap to knock it loose. Just fyi, when two different metals are in contact for a while the galvanic corrosion can make them very difficult to separate later. Could be what has happened here.

[terrible one]

Thanks for the info guys. For a stroke of good luck, my new neighbor happened to have a set of taps which I borrowed. Back in for now but Ive been soaking it in some PB every couple of hours so Ill see what can be done tonight. I may have no better luck than with the bolt but we will see. I just wish I would have noticed this before the engine was in the car!

[b5blue]

GOOD LUCK! 

[tan top]

GOOD LUCK! 

  fingers crossed ...........

[mikepmcs]

Get a little propane torch and heat it up.   

[R2]

 

[Corellian Corvette]

HEAT HEAT HEAT! Everyone forgets about heat! Get that area NICE and hot. Expanding the metal will not only make it softer, but burn off any rust/scale that may be "gluing" it on there. Heat!! 

[terrible one]

The taps did not work. One went in but when it came time to try to apply force it just stripped out. I've been out there with the car again since leaving school and it defeated me again. I want to get a torch from walmart but I don't have the money yet. I have done everything else I can think of. I was going to drill it out but couldn't even get my oil pickup, which is in the way, to come off either. This is RIDICULOUS. I don't understand what has this so stuck in there. I've been working on this car for almost five years now and as the light gets closer everything caves in in front of me! I don't even enjoy working on it lately because it's been leaving such a sour taste in my mouth.

Hopefully I will be able to drill it out or will have the money for the torch once I feel like messing with this again.

[oldrock]

I think we have all been in similar situations where you just cant seem to get a project completed. I know we have had a recent ignition issue with my son's charger giving us fits. Sometimes it just takes giving it a few days so the made goes away and you can start fresh on it again. Keep working at it and you will get it.

[FLG]

Take a break from it and come back.

I bet when you get that thing out your gonna feel like a million bucks 

[b5blue]

Hang in there the last 20% of any job takes 80% of the effort! Anything made can be mended. 

[Cooter]

Getting one of these out of the block is not an easy job......It takes some finesse to get it out..It's not gonna just slide right out...These things are a PITA...The reason they are a press fit into the block is to control an oil leak where the dipstick goes in at.. you will have to use a  hammer from under the car to tap up on it...You think this is a PITA, be thankful you didn't get your FRESH 440 back in a 1958 Plymouth only to have the damn rear main seal (BRAND NEW??) start pissing oil like a cow pissing on a flat rock.....Didn't even get to drive the damn thing out of the garage...Good luck...

[John_Kunkel]

The hole in the block is 23/64" but it's not drilled all the way through so this prevents getting a bite on the tube from the bottom. Weld a plug into the remaining part of the tube and then you can punch it out with a 1/4" pin punch.

[flyinlow]

I removed a broken off pickup tube with an Irwin bolt remover. Dont know how much is left sticking out. Would need about 3/8 inch.

I think Johns idea above sounds promissing. Becarefull welding on an assembled engine, Weld wire wont stick to cast iron block  ,but crank to bearings can . Make sure the ground is good and close to the dipstick tube.

[squeakfinder]

  Plus the heat will help break it loose. This is crazy, I've got two big blocks that the dip stick tube won't stay in. 

  Most major projects I've done at home or work, require some (or a lot) of bugs to be worked out.
Hang in there  .
   
   

[terrible one]

Thanks again everyone. I got it to move a bit. There is no longer any of it sticking out. I will try my luck again when I can get a torch!

[oldrock]

if you got it to move, you are probably home free. ONce the rust breaks free, it is probably just a matter of driving the stuck part on out. Might be able to get it now without the torch. Now that it is moving, I'd soak it with some penetrating oil and see if you can drive it on out. Good luck and be sure to report back when you do get it out of there. Always nice to get closure on these things and here what finally made it happen.

[TylerCharger69]

I had to file away at the insides of one before with a real small skinny file...in other words..file until it breaks through the sides....i did that on opposite sides....finally came out with a ball peen and a punch

[b5blue]

Try a rat tail file in a drill. 

[TylerCharger69]

Rat tail file....that's it!!!