Every connector in the drivers side (4) broke when trying to remove.The remainder of the rubber boot still in the engine frozen to metal. Can't pry them out. Got one out with some careful drilling, but the other 3 are pretty much inaccessible with a dremmel or drill. Haven't tackled the passengers side except to verify they too look frozen and ready to break.
First thing I did when I started the tear down. Still not enough room. I have ordered a flex attachment for the dremmel, may be I can chew them out with it.
Can you (carefully) melt them out? A small propane torch may do the trick. Enough heat to soften them may allow you to dig the remnants out with a suitable tool.
Using 4" wood screws, I have been able to get the plugs out of the drivers side. 2 plugs on the passengers side came out with 18ga wire. #1 & #3 broke and need to be drilled and screwed. ugg.
Got the last two out. They were actually easy compared to what was on the driver's side. Buggered one of the ports (2nd one I drilled) but doesn't seem to be in the area that the o-ring sits. I know more when I can get a bore scope camera on it and hone it some. It's 107 outside, so I am stopping now. Pulling the plugs and compression tests in the morning.
Using a drill where you cant' get close to straight and even tell what you've been destroying. As I mentioned, successfully drilled other ports with a dremel using a debur bit (3/16") that was about 1.5" long. Best to drill at a angle across the rubber from above or below the wire: and maybe 3/4" max depth. Screw in a 3" or 4" screw and find somewhere you can get vise grip around with some leverage and then Pop.
Nothing to debur in the port it doesn't look like metal flakes enter it.. Maybe coat with some hi-temp sealer and let cure before replacing the harness.
I had the same problem with 3 out of my 8 GP's. I used a flexible inspection camera to monitor as i drilled into the snapped off boots with an angle die grinder and a small drill bit. As was mentioned before, I drilled them at an angle to ensure I had enough material to have the pry tool bite into the boot. They all came out with no issues other than i actually drilled too far into one of them and my bit went into the block about 1mm. This freaked me out but it's been ok so far. Thankfully the block is a little thicker than 1mm ?
I think the die grinder had too much power and just pulled the bit into the boot pretty quickly. If I had to do it over again, I'd use a slower speed dremmel to ensure slow penetration into the boot.
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