the world's most stubborn 02 sensor.
 

this past weekend we BATTLED with the O2 sensor in our 944 trying to get it out. we didn't want to bust anything so after 4 HOURS trying to get it to move, we brought it to a muffler shop. now THEY can't get it to budge either. they said it's pretty much welded itself into the pipe and no amount of heat or tools is moving it.

they also said that it would be smarter and cheaper to just get a replacement pipe and put that in. the only other solution is cutting it out and welding a nut into the pipe.

am i the only person this stuff happens to :rolleyes: ? please tell me i'm not just cursed.

also, anyone have an extra 944 pipe they want to sell? part number 944.111.987 01

thanks!

obin

You will have to take the whole pipe down. Once you have it on the bench you can do all sorts of things to it. For example you can drill it out, but make sure you don't destroy the thread.

(insert raising hand smily here)

I'm with ya Obin!!

Mine was stuck in from the previous owner screwing up the threads. It took all my strength to get it out and when it finally came out the threads were so messed up, on the inside and outside. I didn't have anything to retap the threads so I put the new one in. It was even harder getting the new one in and I still didn't get it the whole way down. Oh well, I will just have to get a new downpipe if I decide I need to change it again.

you're cursed. mine came off by hand.

Sorry to hear about the difficulty. I guess that if the PO didn't put anti-seize on the threads and its been in there a while you just may be "stuck".

I'm a big fan of PB Blaster but suppose you've tried that already. Otherwise, any good muffler shop should be able to but the old one out, and patch in a new bung. Not too difficult at all.
Good Luck and let us know how you ultimately solve it.

Obin, its your fault for living in the snow-belt of the Northeast! I lived in Troy for four years. Straight to California afterwards and no more rusted bolts!

same here
 

Oh god does this bring back the memories. LOL! I had the same problem on my 87 NA. I live in CA, but the car came from PA originally....why do i buy cars from the rust belt when i live in CA? LOL! Anyways, i tried PB, WD-40, two wrenches, cursing, torch, nothing worked. It was just frozen on there. I eventually ended up stripping it because the wrench tore the corners off of the nut. Doh! I promptly went down to the muffler shop where they welded another bung in place. I think it was like $50 or something around there. The old one is still there, when i get headers i pull it out...till then, its a "feature".

I have not encountered this exact problem with an O2 sensor but similar problems with exhaust bolts. I have found greater success if you:
1. Run the car until warmed up
2. Turn it off and wait until the part is cool enough not to raise blisters.
3. Squirt the ***** out of it with liquid wrench.
4. Turn real hard!

I would do like Mikey & grind the old bung off & either weld or have another welded on.


drew1

Hey Obin, I'll trade you problems! I can't keep mine tight.

I've tried a new copper "crush" washer, all the different colors of Loctite, torquing the crap out of it, and all combinations of the above. But after about two weeks, it's rattling again! The threads are good, and clean, but it just won't stay tight.

Thats how mine was originaly. Thats why I decided to change it but the threads were messed up. It doesn't rattle now, just won't go in all the way or won't come out.