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Origional 02 sensor stuck! Help!

  • Thread starter Thread starter jhammel85
  • Start date Start date

jhammel85

Guest
Hey Everyone,

Well...I had a hell of a time today working on my truck. I went to replace the O2 sensor and it was completely frozen in place. I tried heating it, using leverage and nothing worked. I actually bent 2 breaker bars trying to get it loose. They are craftsman so at least I can get replacements.
on the 3rd, it completely stripped the bolt when it got loose from me. So now, its almost completely round.....I broke the top off so I could use anything I want after it gave me a lot of crap so I can still work with it. I think...But what would you all recommend? There isnt much space at all under there, plus the angle doesnt help.

There isnt a way to drill it out or anything like you would normally do when something is stripped.. I was going to pull the Y pipe down and get this part out the right way (at this point) but I'm really scared about breaking the bolts loose at the Exhaust Manifold flanges. If they snap, then I'd have to take the exhaust manifolds off... Anyone have any ideas for removing those bolts? Something you've done that would help?

The only other thing I can think of is I may pick up a bung for the 02 sensor and basically relocate the sensor right next to it. The wires are plenty long enough to do this. It'll be right next to it just maybe on the other side of the pipe because it'd be much easier to weld that way. It'll still be in that little bridge....Do you think it would throw off the computer?

Bottom line is...I'd like to get this thing out before anything. Any ideas on getting it out of the bung at this point???
 
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It's easiest if you drop the Y pipe, you will need a oxy/acetylene torch to heat the manifold up to red hot and try to get the bolts out, then heat up around the o2 sensor till it's red and take it out, if you do end up breaking off the bolts in the manifold just blow them out with the torch and use bolts and nuts
 
Thanks. I might do that. The thing is, what do you mean by blowing them out with a torch? There isnt much space at all under the truck to get to the bolts so if something happened, I would imagine that I would have to take out the exhaust manifolds. Wouldn't the bolts be stuck on the flange for the manifold?


I'm also somewhat thinking about getting a 7/8" bolt extractor...But in that case, I'm kind of thinking that I might be right back to where I am right now...It may not be worth it..
 
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I had drilled the manifold bolt completely out,(slightly over sized), for the Y pipe flange end....I did have it , the manifold off, but in a pinch, thought one could get it done without removing the manifold. then just ran longer bolts and used self locking nuts so that they wouldn't back off.

Once the Y pipe is off i'm sure you'll get at it well enough to get it out. If...you can't get it out just cut it of or grind it off and weld in your new Bung.

with it off, it would be MUCH easier to access the over all condition...might be better to get a new one ( Y pipe that is)...the old one might not be worth fighting with.
 
it is possible to blow the bolts out with a cutting torch, you might have to play around to find the best plan of attack but it is doable without removing the manifolds. you will break off every single manifold bolt when you try to get them out.
 
Thanks for the help.

Well, I think I might give it another go tomorrow night. Its not completely gone but it was pretty bad last night. its soaking in PB Blaster right now and it will be tomorrow too before I work on it. I didnt have it yesterday..just good ol WD-40.

I'm thinking about using a pair of channel locks and torquing them down a little more with pliers to really dig in...Then hopefully my breaker bar around its handle will be enough to break it loose.

I'll let you know what happens!
 
I have it soaking again in PB blaster and Kroil. I'm hoping its enough to break it loose! I plan to work on it tonight @ work. We have impacts and we have better tools for removing stripped bolts, like a boltout kit. Hopefully one thats big enough (7/8")

Its running terrible right now. Actually for some reason the door chime has changed tone. Has anyone ever heard of that happening? Does it mean something? It did this when I reset the computer too. After a few days it went back to another ding. Weird......
 
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Update:

No luck last night...even while welding a socket to it I just could not get it loose. Crazy isnt it?

Well...I've got a battle plan for Saturday, my next best day. I plan to take the Y pipe down from the exhaust manifold flanges and cat. Hopefully with a little bit of heat it'll come right out.

Anyone have pointers on removing those manifold flange bolts? I found a post where someone removed their splash guard and wheel to access those bolts. Hell of alot easier IMO...That way someone can spray it down while the other breaks it loose....

Thanks for everyones help so far BTW!:beer:
 
jhammel85 said:
Update:

No luck last night...even while welding a socket to it I just could not get it loose. Crazy isnt it?

Well...I've got a battle plan for Saturday, my next best day. I plan to take the Y pipe down from the exhaust manifold flanges and cat. Hopefully with a little bit of heat it'll come right out.

Anyone have pointers on removing those manifold flange bolts? I found a post where someone removed their splash guard and wheel to access those bolts. Hell of alot easier IMO...That way someone can spray it down while the other breaks it loose....

Thanks for everyones help so far BTW!:beer:
Click to expand...

Yeap ....on the right track
 
Alright...New 02 sensor is in!

I didnt bring the Y pipe down because I was able to cut the bung out. I cleaned it up, removed the old O2 and rewelded. The trucks running much better! I still have one last problem that I hoped this would fix.....

Running, driving and idling is fine but when I shut the truck off, warm and I get back in, the truck starts fine but starts to stumble about 20 seconds after it starts. Pretty much right when the truck is lowing its RPM and adjusting idle. After a few seconds of missing like crazy and kind of lopes then it finds itself and drives perfect. Maybe a Temp sensor (ECM)??

I've done the oxy sensor, air filter and I've cleaned the IAC valve. No luck......
 
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jhammel85 said:
Alright...New 02 sensor is in!

I didnt bring the Y pipe down because I was able to cut the bung out. I cleaned it up, removed the old O2 and rewelded. The trucks running much better! I still have one last problem that I hoped this would fix.....

Running, driving and idling is fine but when I shut the truck off, warm and I get back in, the truck starts fine but starts to stumble about 20 seconds after it starts. Pretty much right when the truck is lowing its RPM and adjusting idle. After a few seconds of missing like crazy and kind of lopes then it finds itself and drives perfect. Maybe a Temp sensor (ECM)??

I've done the oxy sensor, air filter and I've cleaned the IAC valve. No luck......
Click to expand...

have you cleared any codes that were there....disconnect the battery at least 10min and drive until fully warmed up.

then retest for codes
 
Thanks but I did reset the computer by unhooking both terminals today. I will try to get codes ASAP but the diagnostic connector has been disconnected by the previous owner...I have a post about it somewhere.

I just drove the truck and what it seems to do is when its started or when its warm and at idle, it'll hunt for idle. It'll bounce between 500 and 1000. That only happens after its been idling for a minute or two. Never happens when cold which is probably due to the fact that it idles much higher when cold.:dunno:

Also...I checked the FPR....No problems. It smells like gas in the vac lines but no actual fuel......
 
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Do you think that its a possability that the Engine coolant sensor is bad? I would think it could be since it craps out when its hot BUT...what about when its at idle and it starts to hunt idle when its been sitting for a few mins?

ugh....Like I said..I wish I could check for codes but I cant....Thanks for everyones help, btw
 
jhammel85 said:
Do you think that its a possability that the Engine coolant sensor is bad? I would think it could be since it craps out when its hot BUT...what about when its at idle and it starts to hunt idle when its been sitting for a few mins?

ugh....Like I said..I wish I could check for codes but I cant....Thanks for everyones help, btw
Click to expand...

might have to try a new IAC....or try cleaning again
 
Is that what sounds most likely to you? Cleaning did nothing the 1st time I did it. I cleaned it very well...Also, when I had taken it off, I made sure that it moved when I turned the key. It moved perfectly.
I was thinking about testing the voltage off of it but I cant find anything on the tech library page or my haynes manual on what voltage it should normally be at.

I'm really thinking between the engine coolant temp sensor that goes to the ECM and the IAC valve. The thing is, with the idle sweeping the way it does, I dont know how much that would point to the AIC valve.
 
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