Need help with 2015 Impala expansion valve replacement

[i6pwr]

I'm replacing a few items in this AC system, and while it's evacuated, I will also replace the expansion valve.

The problem is, GM did us a solid and ran the brake lines over the manifold.

The threaded post can be removed with an E7 external torx, but I believe it's slightly seized maybe from repeated hot/cold cycles. I was using way more torque than I was comfortable with given the fact it's attached to the evaporator and that would be a nightmare to replace.

Any tips on removing the threaded post? The brake lines don't look like I can get enough wiggle room to get the manifold past that stud.

 

[zfasts03]

maybe lock 2 nuts on the threads the put a socket or wrench on it. it still a risk though.

 

[i6pwr]

I don't want to start a new thread, so I'll just bump this one.Does anybody have any tips or tricks on how to get this valve off?

 

[i6pwr]

maybe lock 2 nuts on the threads the put a socket or wrench on it. it still a risk though.

I'm sorry for the late reply....I can get a solid bite with the external torx .I just cannot get it to turn.

 

[chemman]

Spray it with some Knock'er Loose or other penetrating fluid, let it sit for a few minutes then tap the head of the bolt with a hammer, apply some more Knock'er Loose, and repeat with the wait and hammer.

 

[clinebarger]

Id use a impact with the E7....If the tip breaks off, Weld the nut to the stud & use a 13mm with an impact, Of coarse you would need to replace the stud & nut.

 

[Nukeman7]

If you believe the threaded stud is stuck due to thermo cycling/corrosion, I would suggest heating the stud with a fine tip propane torch and applying some penetrating oil to loosen it up.

 

[i6pwr]

Id use a impact with the E7

I want to also agree that the impact shock might break it free. The only part that worries me is how it's all connected.

The manifold in the pic above is the end of the lineset in the engine bay as it enters the firewall.

The expansion valve pictured below is what the lineset is bolted to with the single stud, I also put the 2 mounting torx bolts in the expansion valve for reference.

The part that worries me, is the expansion valve is sandwiched between the AC line manifold in the engine bay, and the manifold at the end of the 2 lines from the evaporator pictured below.

The 2 smaller bolts secure the expansion valve to the evaporator. My fear is if I apply too much force to that torx stud, I could possible damage the evaporator lines inside the HVAC box since the 2 smaller torx bolts still have it secured to the evaporator.

Perhaps it can take more force than I realize..but it definitely adds a sweaty palm moment to the procedure....lol.

So why can't I just remove the 2 smaller torx bolts is another question...I cannot get the engine bay side manifold off the stud as I don't have the slack to bend or extend the lines that far. The trick (I believe) is to remove the nut, then the stud so I can swing the lineset out of the way.