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#585184 - 09/11/06 03:34 PM Need tips to remove stuck oxygen sensor
Cutehumor Offline

Registered: 12/10/02
Posts: 9364
Loc: USA
I have a 14 yr old/133k oxygen sensor I need to take out. I removed the heat shield. The day before, I sprayed PB blaster on the o2 and tapped it with a hammer. Then the next day, I warmed the car up for a minute to get the exhaust manifold hot without burning my hand. Then used a crow style Oxygen sensor removal socket, but the oxygen sensor won't budge. To give you an idea how stuck it is, I didn't jack the car up. My car was rocking backwards on the force I was pulling that torque wrench. Anything else I could try without breaking the 02 sensor off?

#585185 - 09/11/06 04:03 PM Re: Need tips to remove stuck oxygen sensor
TooSlick Offline

Registered: 08/02/02
Posts: 5785
Loc: Dixie
Cut off the exhaust pipe from the Oxy Sensor back with a Sawsall? [Wink]

Seriously though, you tried all the things I'd do, but rather than a straight pull, I'd try gently tapping on the socket with a metallic hammer to shock/vibrate the theaded fitting. I find this works for tight nuts. If you had a box end wrench you could use instead of the socket, that would be better, since you wouldn't be putting bending loads into the sensor.

You could also try chilling the sensor with dry ice to get it to contract.


#585186 - 09/11/06 06:10 PM Re: Need tips to remove stuck oxygen sensor
johnd Offline

Registered: 03/02/05
Posts: 621
Loc: Austin, TX
It may not be practical for you but the only way I can ever get exhaust system components out is to heat them cherry red with an acetylene torch. MAP gas would probably work and would be a lot easier to get hold of. I don't think propane would cut it unless it was a really big torch. Once they are that temp they may squeak a little coming out, but they will come out.

#585187 - 09/11/06 07:19 PM Re: Need tips to remove stuck oxygen sensor
labman Offline

Registered: 03/14/03
Posts: 8711
Loc: Nothern USA
The purpose of removing it is to replace it? Don't spare the hammer. For the best of BITOG, see;f=24;t=000035#000000

#585188 - 09/12/06 04:58 AM Re: Need tips to remove stuck oxygen sensor
mechtech2 Offline

Registered: 09/05/06
Posts: 19479
Loc: Chicago Area
Break the old one off, so that you cn use a nice six point socket on it - flank drive if available.

#585189 - 09/12/06 05:07 AM Re: Need tips to remove stuck oxygen sensor
HardbodyLoyalist Offline

Registered: 08/06/04
Posts: 707
Loc: Lower Alabama
Two words: "breaker bar"

BIG, BIG breaker bar.

#585190 - 09/12/06 05:19 AM Re: Need tips to remove stuck oxygen sensor
Eric Smith Offline

Registered: 02/26/05
Posts: 2917
Loc: Kansas, USA
PB blaster and let it soak over night. PB Blaster it again and let it soak again for a couple hours. The put a good sized breaker bar on something other than a torque wrench. I've only had one strip out on me and it was a gm piece of junk. And apply constant steady pressure.. unless you have a impact gun handy.

#585191 - 09/12/06 05:20 AM Re: Need tips to remove stuck oxygen sensor
alreadygone Offline

Registered: 01/04/06
Posts: 3161
Loc: North Arkansas
Follow mechtech2's advice, also use labman's hammer on the end of Hardbodyloyalist's breaker bar,,, BUT only after running engine till it's hot as johnd suggested. I know it's uncomfortable under there with engine compartment hot, and you may burn your pinkies, but that's why you have to pay us professionals more than you think it's worth !


#585192 - 09/12/06 04:03 PM Re: Need tips to remove stuck oxygen sensor
Cutehumor Offline

Registered: 12/10/02
Posts: 9364
Loc: USA
I got the oxygen sensor out! I like to thank you guys for giving me tips. I needed every one of them. I soaked the sob with PB blaster over several days, drove 30 miles, put an entire stick of candle wax on the threads immediately, went out and bought a big breaker bar. hammered it. with o2 socket plus breaker bar, it did the job. As you can see, I didn't have to break the o2 sensor off and I didn't strip the threads out either. I went ahead and placed my order for a denso OE o2 sensor with Thanks again. [Cheers!]


#585193 - 09/12/06 04:35 PM Re: Need tips to remove stuck oxygen sensor
chrome Offline

Registered: 07/04/04
Posts: 406
Loc: Melbourne, Australia
Just remember to apply some antiseize which should come with the new O2 sensors. My Denso ones came with small plastic tubes of copper antiseize, which I applied sparingly on the threads. Never had a problem removing them again.

#585194 - 09/13/06 10:37 AM Re: Need tips to remove stuck oxygen sensor
TheTanSedan Offline

Registered: 10/15/02
Posts: 1880
Loc: Corpus Christi, Texas
This was a job for some LC-20, a wire brush and then some KROIL.

#585195 - 09/14/06 09:30 AM Re: Need tips to remove stuck oxygen sensor
ekrampitzjr Offline

Registered: 03/23/03
Posts: 788
Loc: Hopewell, Virginia, USA
Can't emphasize Chrome's point enough when you install the new sensor. Use the antiseize! Use the antiseize! Use the antiseize!

It has been apparently common practice on the assembly line for many automakers never to use antiseize on threads where it was obviously necessary, such as on spark plugs, oxygen sensors, exhaust manifolds, and the exhaust and EGR systems. Makes it a pain to maintain or replace later, especially when the part is barely accessible for the necessary wrench.

#585196 - 09/25/06 01:18 AM Re: Need tips to remove stuck oxygen sensor [Re: ekrampitzjr]
Bernard Feltzer Offline

Registered: 01/10/06
Posts: 58
Loc: USA
Never ever use antiseize on sparkplugs, especially with aluminum heads.

#585197 - 09/25/06 06:20 AM Re: Need tips to remove stuck oxygen sensor [Re: Bernard Feltzer]
dkcase Offline

Registered: 10/20/02
Posts: 732
Loc: Suburban St. Louis
Could you elaborate as to why you advise that ?
It's pretty standard to use anti-sieze where dissimilar metals are joined.
Concern for heat transfer to the head ?

#585198 - 09/25/06 12:24 AM Re: Need tips to remove stuck oxygen sensor [Re: dkcase]
toocrazy2yoo Offline

Registered: 12/05/05
Posts: 2724
Loc: Herndon, Virginia
I hit the spark plug threads with a little silicone spray tp ease the installation, but not with any intent toward anti-seize. Not over-torquing takes care of that.

Oxygen sensors and the like, they're in service for so long, would you really expect anti-seize to still be in play years later?

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