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Separate old aluminium coolant pipes to replace O-Rings

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My 2005 4.5l Cayenne last had replacement Aluminium coolant pipes done in 2010.  Since then, it has covered 100k so clearly need to renew the O rings.  Question: does anyone know how to separate the 3 pipes into the upper thermostat housing ? They seem to be well and truly stuck in there. I tried heating it a bit and only managed to move it a little bit out but I am concerned with the fragile Aluminium that I could damage them if I continue with brute force. 

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  • 2 weeks later...

Hi there,


I can't believe no one doesn’t know how to safely separate these pipes as I have already damaged the delicate tabs on one set and now bought a replacement so don't want to damage another set. Is there a tool for this as right now I am totally defeated

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I think you’re gonna need to employ a little ingenuity and care in separating them. Whatever you do I wouldn’t heat them. Perhaps you could DM the Admins for assistance. There are also some good videos on YouTube

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Thanks @GSpence2 I agree heat is not the right way to go. I am just surprised no one else has ever encountered this problem before. I also don't think brute force will work either as that is how I broke off the delicate tabs.  I saw one video on youtube which involved brute force hitting the tab with a hammer which I will not be doing. Any other suggestions?

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