In this video we'll go over how to extract a broken off heater hose quick connect coupler from the aluminum coolant cross-over housing of the GM 6.5L turbo diesel using the Lisle 62450 toolset. Due to the pot metal (a Zinc alloy) construction of the factory part these tend to break off at the neck when you attempt to extract them with a socket. You usually first notice a problem when you detect you're leaking DexCool coolant at one of these connectors. While they last for a fairly long time, they are almost always a significant amount of labor to fully repair when they fracture from corrosion and metal fatigue as we'll see.

NOTE: While you could do this repair with the cross over still installed to the engine, there is a high risk of pot metal debris from the quick disconnect fitting falling into the thermostats housing or even the cylinder head. I do recommend doing the repair off-vehicle as I've shown.

The vehicle illustrated is a 1999 Chevrolet Suburban LT, but the repair would apply directly to any vehicle with the 6.5L turbo diesel across 1996, 1997, 1998, 1999, and some carry over old body style (OBS) models into 2000, 2001, and 2002. That would be for Chevy, GMC, and Holden across Suburban Tahoe Yukon Silverado Sierra, Cheyenne, W/T as well as G Vans.

The eBay and Amazon search links below are paid links, for which I may be compensated and earn a commission, if you choose to buy the parts and tools shown in this video thru them:

Lisle 62450 tool I used to make this repair: https://ebay.us/ohZGNE

Replacement GM quick connect coupler unique to the 6.5L diesel engine. I recommend you only purchase if it's the latest machined steel type, which will have a yellowish zinc chromate finish on the outside (GM 24503682 which superseded 10234142): https://ebay.us/Gwr4uI

You can also switch to a ACDelco 15-30569 hose barb (GM 12597484 and superseded 15963984): https://ebay.us/3UHtYk

6.5L diesel coolant crossover thermostat housing: https://ebay.us/mcJm8f

ACDelco DEXCOOL coolant GM part 12346290: https://ebay.us/4JxkdT or https://amzn.to/2L8Vwsd

If I've saved you some $$ here, consider some coins for the coffee tip-jar! https://ko-fi.com/drshock

1996 1997 1998 1999 and some carry over 2000 2001 2002

Chapters:
0:00 - Problem overview
2:19 - Coolant quick connect hose removal
3:30 - Coolant quick connect removal
4:48 - Coupler repair kit overview
7:03 - First repair tool approach
9:00 - Second repair tool approach
14:44 - Retapping the threads
18:51 - Thermostat housing removal
21:03 - Final observations

Corrections:
3:23 - I was mistaken here, GM did eventually re-service this part. Link in the description.

#drshock #65diesel #dieselsuburban #chevytrucks

Disclaimer: DrShock, the alias for the human content creator for this YouTube channel, is not responsible for any damages, injuries, losses, or liabilities associated with any repairs, upgrades, or maintenance performed on yours, or any other, vehicle whatsoever. No warranty, express or implied, is made as to the accuracy or completeness of any information provided within this channel. Viewing and using the “as-is" information of this channel is totally at your own risk. Always wear personal protection equipment and follow appropriate vehicle manufacturer service manual guidelines with original manufacturer parts only when performing any repairs, upgrades, or maintenance upon any vehicle.