Removing intake manifold S1 FHC

[JohnB27]

Hi,
So the throttle linkage bushing closest to the bulkhead on my '66 S1 FHC is shot. Initially, I thought this would be a quick and easy repair, but the deeper I got it became apparent that it is far from it. After googling and watching some videos (thanks davejaguar66) I decided to bite the bullet and remove the entire intake manifold/carb setup. After spending the good part of a day removing the 18 manifold bolts, 3 of which were close to impossible, the heater hoses and disconnecting the linkages I was finally ready to remove the entire intake structure. Well, not so fast! It will not budge. even with penetrating fluid and light pressure from a crowbar between the forward part of the manifold and head. After a second day simply trying to remove the stuck manifold I am out of ideas. I replaced the exhaust exhaust system with a SS setup including headers and the exhaust side came off easily. I thought the intake side would also then, but no luck, it must have been replaced with some kind of adhesive. The engine was rebuilt in 1990, but has seen little use since. Does anyone have any tips for removing a stuck intake manifold?

Pics are the throttle linkage bushing and intake manifold.

davejaguar66 throttle linkage video:

[mgcjag]

Hi John...to remove mine when i thought it was siezed on....lay a towel or thin foam along tbe top of the manifild to protect the surface....on top of this a piece of 3×2 timber.....then the scary bit......whack it with a mallet...mine took a few hard whacks then i felt tbe gasket give......all the best.. Steve

[JohnB27]

Thank you, Steve. I just tried that, demolishing two 3x2's in the process, but still no movement...

[mgcjag]

Try squirting penetrating fluid all around the joint and bolts and leave overnight.....then try again

[JohnB27]

Ughh!!!
I just made a couple more 3x2's and gave it another try. When the second 3x2 gave up and split the hammer landed between the #2 & #3 carbs bending the throttle shafts!!!

What an extremely frustrating couple of days for a crappy rubber bushing!

[Mikael B]

Hi John
Removing the intake manifold can be very difficult and usually requires allot of force.
I have no bright ideas about this then other mentioned.
However I had the same problem replacing this throttle linkage bushings on my 68 E-type. After fiddling a while I inserted the bushing from the bulkhead side and pressed in place with a small block key. This is not the way it's shown in the parts catalog but I guess the bushing does mind which way it's installed. Worked very well on my car.
Regards Mikael

[abowie]

If it won't budge leave it.
It's tricky but you should be able to replace that bush and reconnect the linkages without removing the carbs.
Try leaving the little bolt in, wangle the two ends together. then with the two at as much angle as they'll allow slide the bush IN the bracket over the end. bring this up to the firewall and then bolt it in place.
For the lower manifold nuts I use a stubby ratchet spanner. This will fit on all but 3 or so of them.Bring your arm in from the front, under the manifold. The end ones can be got with a socket on an extension.

[JohnB27]

Ughh!!!
I just made a couple more 3x2's and had at it one more time. As the second 3x2 gave up and split the hammer deflected and landed between the #2 & #3 carbs bending the throttle shafts!!! 2 won't turn at all and 3 is warped. Now I probably need two new carbs, the aluminum housings could be damaged leading to air leaks in the throttle shafts.

What an extraordinarily frustrating couple of days, all for one crappy little rubber bushing!
And to make matters worse, the manifold remains stuck.

[abowie]

Ughh!!!
bending the throttle shafts!!! .

Yep, that's rooted, as we say in the Antipodes.
Take the carb off (not impossible on a LHD car) and get it fixed.
I would still advise against taking the manifold off if it's that seriously stuck.

[Mikael B]

On the positive side, removing carburettor will also give access to the linkage system under the manifold that can be easier removed and bushing replaced.
Mikael

[JohnB27]

Thanks guys. Yes that's my plan now, remove and repair the carbs. and try to replace the linkage with the manifold in place. Should be easier with the carbs off.