Here is another Contribution in re-payment for all the help on this Great Forum!
Thanks Pelicans!
All right guys, you've changed your 02 Sensor only to find the male connector crumbled as soon as you pulled off the old sensor rubber cover. Revealing a green wire and stab. What the Duck
What the Heck do you do? Take out the electrical tape, silicon glue, or even cut the brand new O2 Sensor rubber sleeve so that you can insert the stab?
Unfortunately that yellowish plastic part is not replaceable and one must invest $800-1300, yes $800-1300 to replace the entire harness which is connected to the DME, UNACCEPTABLE! (Thanks SloDave for the info) Part area #1
Here is my humble fix:
Total Cost =
$1.29 USD
1" Nylon Spacer $0.33 (1"x1/2"x 1/8 dia. whole)
1/2" Nylon Spacer $0.30 (1/2"x1/2"x1/8 dia. whole)
Male DIN 8 Pin Connector $0.63 (only need the sleeve to fit the 1/2" outer diameter of the spacers)
Sales Tax: $0.03
1. Take off the rest of the yellowish plastic, it is dust anyways.
2. Crazy Glue/ Epoxy the the spacers together
Note: There must be a good reason for the engineers to put so much rubber around that connection. Errand sparks i.e. electrical fire? I do believe it is the heating wire for the O2 Sensor (Vets please correct me if I am wrong)
3. Using a carving/engraving Dremel tool, cut an 1/8' slot down the side center and a divet to match the locking divet in the New O2 Sensor. Use a clamp for better support
4. Bevel the the two ends so it will slide into the new O2 Sensor's protective rubber sleeve and the DIN 8 Pin Sleeve, It will make your Mod Part slip on more easily while working in the engine compartment. You may choose not to use the DIN 8 Pin Sleeve but I figure I would add extra insulation for this area.
I used a bit of lube on the DIN 8 Pin side to make sure it won't be difficult to slip on inside the engine compartment. The new O2 Sensor side is perfect, just don't over dremel the divet, test to fit.
5. Test with old O2 Sensor
Note the stab is a hair wider then the 1/8" whole but with the slot, it will fit. I decided to use liquid electrical tape to ensure the stab and wire will stay in place.
Caution, It is tight in there becareful not to damage the 3 plugs on the brass harness, the one with the CHTS and Ref/Speed Sensors. I detached and moved them out of the way. It allows more room to manuveur.
I tested this with only a 1/2" sloted spacer it worked but was too short to be supported by the bracket. this new 1.5" length is almost the same length of the OEM.
Break a Leg.