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1999 - 2003 7.3L Power Stroke Diesel  
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HEATER HOSE REMOVAL

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Old May 22, 2015 | 07:46 PM
  #1  
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HEATER HOSE REMOVAL

Finally got around to repairing a coolant leak at those two quick connects at the firewall going into the heater core. WOW, what a real pain to remove them. I even had the U-shaped tool for removing the fitting but the connection is so close to the firewall it is almost impossible to reach back in there to use it. I used a small pair of Vise Grip needle nose locking pliers to squeeze those two stupid plastic clips and pulled it off. I actually did finally get the second removed using the specialty tool.
I did not install new quick connect fittings - simply installed new heater hoses and used stainless hose clamps. My only concern is that the heater core pipes were not barbed but I nailed the hose clamps to assure they will not come off.
Both core lines were 5/8" - I thought one was 3/4" and the other 5/8".
I removed the air cooler pipe on the passenger side to allow a little more access. Either way for me it was a knuckle scraper process.
Oh well, tomorrow I will put a few things back together and install my coolant and do a test to make sure there are no leaks.
 
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Old May 22, 2015 | 07:49 PM
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Haven't done mine yet but its on the list. Glad you got it.
 
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Old May 22, 2015 | 08:32 PM
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hmmm, it was not too hard at all for me. I wonder if it was the tool, I used the Autozone one for $20 (cheap enough to keep) or maybe it was my long gorilla arms. Also a top side creeper seems to make everything easier on these trucks. Now I do remember I had to re-bend the tool to make it fit in there, there was no way it was going to work the way it came out of the box.


BTW Napa sells quick couplings that fit onto the heater core lines and have a barbed fitting on the other end.
 
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Old May 24, 2015 | 07:37 PM
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I think a lot had to do with the tools I purchased from O'Reily's. It was a short u-shaped with a bent tab for holding - maybe 3" overall length; all they had and a couple of the other box stores did not have any. So, that made it so you had to get your entire hand back against the firewall to slip this tool into place and it was still difficult to make it work.
I plan to return these and go by NAPA to check theirs out. I purchased a set of the quick connects just in case I have serious failure on the road - they will likely be easier to simply push on.
 
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Old May 24, 2015 | 08:27 PM
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I'd say the tool is the problem. The one from AutoZone is 21 inches long and pretty heavy, I was really surprised that they had something that good for $20. It came flat but I put the bend in it and it fits perfectly, just reach in there and wiggle it back and forth with a downward pressure while keeping the "U" perpendicular to the groove and they pop right off.
























 
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Old May 24, 2015 | 08:50 PM
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Are we talking those spring-loaded satan's inventions?
Whoever came up with those should mate with the person who invented 'tamper proof impossible to open clear plastic packaging'
 
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