02 sensor issues!!! (Removal)

[Trstno1]

Well-

I tried pretty much everything to get the old O2 sensor out in order to replace it...(heating/penetrating oils/time/ breaker bars). Nothing has worked. Then, the last time I attempted to crank on it the O2 sensor finally broke free, but unfortunately left its threads in the crossover. Does this happen often to other folks? What has everyone done to fix this? Anything? I really don't have the coin to be purchasing a spec 1 exhaust right now......

1. Maybe put a torch to the bung and atempt to use an easy out?
2. Try purchasing a good crossover pipe with a good hole, then break other exhaust bolts getting it out?
3. Weld it closed, and have a new bung welded in ( which would require it to be out of the car )?
4. Try to get at it with a pick/chisel and hammer and break it out?

Help!

[DMCMW Dave]

Well-

I tried pretty much everything to get the old O2 sensor out in order to replace it...(heating/penetrating oils/time/ breaker bars). Nothing has worked. Then, the last time I attempted to crank on it the O2 sensor finally broke free, but unfortunately left its threads in the crossover. Does this happen often to other folks? What has everyone done to fix this? Anything? I really don't have the coin to be purchasing a spec 1 exhaust right now......

1. Maybe put a torch to the bung and atempt to use an easy out?
2. Try purchasing a good crossover pipe with a good hole, then break other exhaust bolts getting it out?
3. Weld it closed, and have a new bung welded in ( which would require it to be out of the car )?
4. Try to get at it with a pick/chisel and hammer and break it out?

Help!

It's kind of a mess any way you look at it.

Best bet - get a good used crossover (with all the aftermarket exhaust kits sold they are not hard to find and shouldn't cost much). Get the hardware (4 manifold studs, 8 nuts and washers). Then you still have to get 4 bolts off the converter and another 4 off the manifold flanges, which are also fun to get apart without breaking.

It's really going to be hard to extract that old one in place, but you may as well try because you don't have much to lose. I'd say try an ez out but only if you haven't been heating it all along. If heat didn't work before it broke, it probably won't work with an ez out either.

My guess is that you didn't get it hot enough. You need to get the bung bright red before you start cranking on the sensor.

[sdg3205]

My guess is that you didn't get it hot enough. You need to get the bung bright red before you start cranking on the sensor.

+1.

Probably my mistake too. Don't use propane. Get a hotter torch.

[dn010]

Any time my sensor wouldn't move I've always gotten away with running the engine up to temp prior to removal, but wear gloves!

[alexwolf1216]

Ive got a crossover I just pulled from my car. O2 came right out, PM me if interested.

[Trstno1]

Alright guys-

I soaked the area with PB blaster once a day for 4 days while waiting for tools to arrive. I ended up purchasing a MAP torch and an easy out set. I got the bung red hot and tapped in the easy out, but.....no go. All I could accomplished was shredding some of the metal from the broken O2 threads in the bung. I feel if I keep going the threads in the bung are going to be shot for sure. What a PITA area to be working - not a lot of room for much of anything.

I'm starting to think that taking the crossover pipe out is going to be my only option. But do I attempt this myself or limp it to a shop that has more experience with this sort of work? Im not even sure If it's even safe start the engine w/o the O2 sensor installed....I'm guessing not. Which unfortunately means a flatbed tow to a shop. However, if I could get the crossover out I could work on it out of the car and if it's screwed ultimately at least it's out for another one to go in. problem now, how to get the crossover out without breaking any bolts. Any suggestions? What tools are people using to get the proper torqe on the nuts holding on the crossover? Should the car be on a lift when attempting this sort of work? Currently, I just have the rear end up on jack stands.

If I break bolts on either the CAT or the exhaust manifolds where the y pipe attach am I commited to a new exhaust system? Or can I purchase replacement studs for the CAT and exhaust manifolds? I'm starting to feel like this job has the potential of going downhill quickly. The absolute last thing I want to do is end up having to remove the heads for a trip to a machinist.

Dammit! After all........this all started with just wanting to replace the O2 sensor to see if it would help with my running rich issue. Easy enough right?

I sure would appreciate any suggestions I can get from people who have removed their own exhaust systems, or have had this particular issue. What did you do?

[sdg3205]

Yup, recall my thread? When I started to remove the cat the bolts broke too. It's a risk.

If they aren't coming out when they're red hot I'm not sure what else can be done.


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[Trstno1]

Yup, recall my thread? When I started to remove the cat the bolts broke too. It's a risk.

If they aren't coming out when they're red hot I'm not sure what else can be done.


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Oh yeah, I remember your thread for sure. I keep checking it to see if there are any updates.

[Trstno1]

Well.....heated up one of the four nuts holding on the cat till it was glowing red.....applied minimal pressure and....snapped bolt

Now that I know this is the way it's going to go I'm worried about the manifold studs that hold onto the crossover going the same way.....not good.....

[alexwolf1216]

CRC Freeze-Off Super Penetrant https://www.amazon.com/dp/B000TFTH00..._qTP6ub1C5KF6H
https://www.amazon.com/dp/B000TFTH00..._qTP6ub1C5KF6H


This stuff worked wonders for me