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Join Date: Nov 2002
Location: Littleton, CO
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O2 sensor removal secrets?

OK, I think I've reached one of those 'teachable moments' - after cracking one socket and twisting another one into a modern art sculpture. You see, I'm trying to remove my O2 sensor.

I've sprayed it with WD-40. Tried a LARGE breaker bar.

Still, it has a mind of its own and will not budge.

Should I run the car around town and then risk it when the pipe is at top temperature?

Regards,

DL
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84 944 5spd
Maint. & Fixes made thanks to the help received on this board:
Rear Hatch Pins, Oil Change, Dash Cover Installation, New Rear Seat, New O2 Sensor, New Ignition Switch, New Fuel Pump Relay, Rear Light Assembly Reseal, Instrument Panel Short Circuit, New Speedo Cable, New Timing belts and Starter.
Old 10-03-2003, 08:13 PM
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Hmmm, mine wasn't all that bad to pull. Heat may help, but I've been using that PB catalyst liquid wrench stuff on tough nuts and it seems to work a lot better. If you can find a socket with the hex on the outside of the base so you can run the pig tail through and then use a large adjustable it might help. I actually ground to flat spots on the outside of a 23 mm socket for a real tough nut/bolt.
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'85 (Early) 944 - Beater
'87 924S - Crunch/Rebuild
'76 924 - Long Gone
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Old 10-03-2003, 08:26 PM
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You may have to apply some heat to get the sensor out.

I had a similar problem the first time I changed the sensor in my '84. Ended up using a propane torch and a pair of vise-grips to get the sensor out.

Once I had the sensor out I used an 18mm spark plug thread chaser to clean up the threads in the bung. Since then all I need to do is break the sensor loose with an adjustable wrench, and then I can turn the sensor out by hand.

You can get a combination 14mm/18mm thread chaser at stores like Pep Boys for under $10.00. This same tool is perfect for cleaning the threads for the plugs in the valve assembly.
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'87 944 India Red
'86 951 Kalahari Metallic
Old 10-04-2003, 05:39 AM
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Use AntiSeize on the threads when you put a new one in.

drew1
Old 10-05-2003, 04:20 AM
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The new sensor should have a small amount of anti-seize on the threads. If it does not, apply a small amount, being sure to keep the compound away from the sensor bulb.

Also, when you splice the new sensor wire(s), do not use solder, use crimp on butt splices.

O2 sensors "sample" the outside air through the sensor wire. This "sampled" air is used as a"reference" within the sensor. If you solder the wires, the molten solder will seal the insulation and the individual strands, which in turn prevents the sensor from "seeing" a proper ambient air "reference".
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Cliff Hipsher
'87 944 India Red
'86 951 Kalahari Metallic
Old 10-05-2003, 07:44 AM
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To echo what Lousailor said, try a product called PB Blaster. The stuff really works.
Old 10-05-2003, 10:13 PM
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im third for PB's. its magic in a spray can. let it sit for a few minutes to soak in.
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Old 10-06-2003, 12:14 AM
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PB's is a winner. Use a long box end wrench.. But then again I took mine out when it was off the car... better leverage.
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TENSION YOUR SOCKS!

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Old 10-07-2003, 10:22 AM
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If all else fails the O2 sensor fitting can be replaced by any muffler shop. Its very commom to bugger up the O2 sensor fitting. Try a torch and make sure to heat the fitting no the sensor.
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Old 10-07-2003, 06:20 PM
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Update

Thanks to all who posted with advice.

I gave PB Blaster a try and wow, it really did the trick. I have to admit I was skeptical that this spray-on stuff could do any good.

Still needed a hefty pull on the breaker bar but this time the O2 sensor moved and all was good!

Regards,

DL
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84 944 5spd
Maint. & Fixes made thanks to the help received on this board:
Rear Hatch Pins, Oil Change, Dash Cover Installation, New Rear Seat, New O2 Sensor, New Ignition Switch, New Fuel Pump Relay, Rear Light Assembly Reseal, Instrument Panel Short Circuit, New Speedo Cable, New Timing belts and Starter.
Old 10-19-2003, 03:47 PM
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