Exhaust question

[GHEN]

OK,

So I have rounded off O2 sensor, it looks like I am going to have to remove the exhaust pipe to get it out.

Heat (both driving and torch) and lots of PB Blaster have proven ineffective.

Can I just remove the section of exhaust pipe that houses the O2 sensor? I believe I can remove the 6 bolts that attach at the exhaust manifold, and then the 3 bolts behind the catalytic converter and drop just that section?

I relize I will also have to:

A) Remove the bottomof the exhaust bracket.

B) Cut the O2 sensor wire.

Other that that am I looking good? Should I get new gaskets when I put the exhaust back on?

Thanks,

GHEN

[John_AZ]

Is there no way a HD vice grips cannot grip the sensor?

Yes you will need 2 exhaust flange gaskets --944 111 135 01

Why cut the O2 sensor wire? It just has a connector by the reference sensors that comes apart.

Kroll seems to be the favorite penetrating oil.

You might have to get a thread chaser if really rusted bad by the O2 sensor hole in the exhaust.

There may also be an old exhaust test pipe by the O2 sensor. Just remove and cap the hole. The pipe is usually rusted in half by now.

The other end of the exhaust pipe should just have a steel donut you can reuse or buy for $30+-

GL
John

[GHEN]

Originally Posted by John_AZ

Is there no way a HD vice grips cannot grip the sensor?

Thanks for the tip, I guess that will be my next step.

Originally Posted by John_AZ

Yes you will need 2 exhaust flange gaskets --944 111 135 01

Thanks, I thought as much.

Originally Posted by John_AZ

Why cut the O2 sensor wire? It just has a connector by the reference sensors that comes apart.

I'm being an idiot, of course I'll just unplug it, when I get frustrated I start thinking about cutting my way out of problems; I should work on that.

Originally Posted by John_AZ

Kroll seems to be the favorite penetrating oil.

You might have to get a thread chaser if really rusted bad by the O2 sensor hole in the exhaust.

There may also be an old exhaust test pipe by the O2 sensor. Just remove and cap the hole. The pipe is usually rusted in half by now.

The other end of the exhaust pipe should just have a steel donut you can reuse or buy for $30+-

GL
John

Thanks for all of the other good advice, as always you are the man!

GHEN

[gtroth]

I wonder if you can get a long enough pipe wrench on there?

[GHEN]

Originally Posted by gtroth

I wonder if you can get a long enough pipe wrench on there?

I cannot, there is precious little space up there as it is. I was able to get a set of Vice Grips on there per John's advice, but couldn't get it to budge. It goes off to the mechanic tomorrow...it really is all about timing. If this were a month ago I could drop the exhaust and work on it but this coming week I can't tie up the garage and I have no spare time; c'est la vie.

GHEN

[mytrplseven]

My car wasn't a rust bucket (not inferring your's is) but when I tried to get the 6 exhaust nuts off, they were rusted and it took a full day with a small air driven die grinder with a cutting blade to cut the bolts off. Very tight in there and you have to be careful you dont' cut one of the pipes. I hope you don't have this problem. Sometimes a single bolt can take days to get off and make you want to take your biggest hammer to it out of frustration. You just have to walk away and clear your mind.

[thekidd]

I had to drop my whole exhaust off to get those (mine were rusted too, 1 nut was actually a "C" and some threads wet rusted through so you could see through the nut). When the exhaust was on, I broke 3 bolts, and later used a punch and hammer to free the bolts. I had to take the engine mount off, and jack the engine a few different ways for it to come down. Some maneuvering by the muffler is also needed.
crap from when I broke the exhaust down to 3 main pieces

[Volhv]

My 6 bolts..... only 5 were installed.
I replaced them, and coated the threads with nickel anti seize.

+1 on the Kroil, It's the best stuff I've tried so far.

[mytrplseven]

This all looks familiar. Too bad there isn't a sound bite to go with it. While I had my system removed, I took it to a muffler shop and had the test pipe hole welded over. My O2 sensor came off easy enough but it was the exhaust to manifold bolts that were a b---h!