PCV Valve Woes

Got a 2004 Dodge Ram 1500 SLT with the 5.7L Hemi. Was changing spark plugs on it and decided to try and change the PCV valve while I was in there. I tried to twist it out and kept twisting and twisting but it wouldn't pop out like everyone said it should. Kept trying to pry at it, and stuck a screwdriver under the top of the valve to try and pry it out and it broke the top off the valve, now the bottom half of the valve is stuck inside the intake. That along with a vacuum leak which makes the truck run horribly. So I tried to take it to a shop and see if they could extract it and they wanted to just replace the manifold and wanted 500 dollars for the part alone! I told them I'll be passing on that and to give me the truck back. So now here's my dilemma. Should I try and extract this myself? Or should I buy a replacement one which is actually about 240 bucks? If I should try and extract it, should I try to do it with the intake on the engine or with it removed? I watched a video about how to replace the intake on the same engine but in a Durango and it required the windshield wipers and windshield cowl to be removed, is this the case for the Rams? Just not sure how to proceed and would like to know your opinions on this first. I already purchased the replacement and have a 45 day window to return it F.Y.I.

Try inserting some long needle nose pliers and open them and pull.

You dont want the Dorman junk manifold. You cant even put oil in it without it burping oil all over the place.

Old Sarge said:

Try inserting some long needle nose pliers and open them and pull.

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That won't work. The valve broke off flush with the hole.

kevkev said:

You dont want the Dorman junk manifold. You cant even put oil in it without it burping oil all over the place.

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You're right. I don't WANT the Dorman one, but might need it. It's the only aftermarket option, and it was the same one that shop was gonna charge me 500 dollars for. There are some other "brands" but they all look identical to the Dorman one, but charged an extra 200 for it. I'm not going to spend anymore than 300 dollars on a hunk of plastic with some included steel and rubber, and I refuse to shop on eBay.

Would one of those extraction drill bits work?

Maybe a screw or two driven into the remains then grip those and finish removing.

I would get a dry wall anchor (the kind that looks like a broadhead arrow and insert that into what's left of the valve

That would give you something to yank on

(just make sure it still fits through the intake hole)

Maybe try a reverse thread screw . Screw it in tight see if it will unscrew the pcv valve. They get stuck from not replacing often enough. Spray some wd-40 see if that breaks the seal loose. Break down the caked oil on it.

The needle nose pliers inserted into the hole and the opened tightly will give you friction to pull out with

ABuchler said:

That won't work. The valve broke off flush with the hole.

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Not sure you understand what Abuchler means. Put the needle nose in the hole of the PCV, with them closed, and then open them up to force them against the inside of the valve and try to remove the remnants that way.

kevkev said:

You dont want the Dorman junk manifold. You cant even put oil in it without it burping oil all over the place.

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Dorman has a good reputation for having cheap replacement parts. Of course that is also the issue, they are CHEAP for a reason, mostly because the Dorman line up is crap. I was saddened to see a show on the Motortrend channel advertise some Dorman aftermarket sh.., I mean stuff, during one of the product ads they do in-show. I know they have to pay the bills same as everyone else, and Dorman paid for the advertising I am sure.

Well. I finally got a day off that it isn't raining all day for and was able to get the old intake manifold out and this is what I'm working with here. As you can see, there really isn't anywhere to insert pliers to "grip on" and pull it out. It appears that the valve has become one with the manifold.

Just found this thread. Taking the manifold off was definitely the right call. I would VERY carefully start removing the old PCV valve from the centre out, that way I could re-use the factory manifold. If you proceed carefully it should work out fine. A little judiciously applied silicone might be needed when you fit the new PCV.

If that doesn't work, I would go to the wreckers and get a takeoff manifold. Let us know how you make out.