O2 nightmares
 

Hey all

just had a bit of a nightmare, fitted a dansk sports cat bypass on to my car a couple of months ago and finaly got the O2 sensor to go in it today, thought this was going to be a 5 minuet job to fit but how wrong could I be!!. Upon trying to get the plug out of the top of the bypass I managed to strip all the threads despite the fact that I had soaked it in WD40 for ages and the heated it with a torch till it was f#=king hot Doh! , it's so annoying I have got to get a mate to helicoil it and fit it for me now nothing is ever simple is it!.
Can any one tell me if there is a secret to doing this without ruining the pipe?

Paul

you can try some antiseize on the threads but if it gets on the sensor it may ruin it...or just get the quick release O2 sensor next time

The O2 bung is the same size thread as a spark plug. Did you try using a spark plug thread chaser to see if you could restore the threads?

My brother mess up the O2 sensor on his V8 Quattro when he tried to replace it. He was able to chase out the old thread with a spark plug chaser.

You should have tried a proper solvent for that purpose. WD40 is not the right stuff - Kroil or PB Blaster. You might also have some difficulty locating someone with an M18-1.5 Helicoil insert. You could try cleaning up what's left of the original threads, weld, drill and cut new threads or cut and replace the bung with a new one (about $10).

Sherwood

Heli-Coil makes a special kit just for the O2 sensor. It comes with the tool and a few inserts. A friend of mine has a few new kits he wants to get rid of so let me know it you need one. Will be cheaper than buying new!