Another stuck Reference Sensor thread :(

[Toran]

Hello All,

Was attempting to replace the Reference Sensor but it seems to be stuck.
I applied some WD40 and Blast but still no removal. I can get it to turn about 180 degrees with some resistance but that’s it.

Any new and creative ways, homemade tools to get this old one out?

T.I.A.

[tamathumper]

WD40 is more of a water displacement agent, and I assume by Blast you mean PB Blaster, which penetrates into rusty metal components. Your problem is probably that old dried up rubber o-ring that is mated to the metal sleeve around it. Got anything that will penetrate and lubricate rubber? Tri-Flow?

[thomasryan]

internet hearsay says WD-40 was developed as a scent for fishing lures. When I bought my first Raleigh Record 10 speed in 1975, the store owner told me to clean the chain with wd then put 3-in-1 on the chain. He said WD is not a lubricant.

I buy pb two cans at a time 'cause someone always borrows one. Good stuff on rusty fasteners.

could you take one of those miniature pry/wrecking/nail puller bars and grind the center out to fit under the sensor?

[gtgt__bangbang]

doubt in this instance you can be free wheeling with the HEAT but I just got a refresher lesson in torching parts to free up. There is a steel special bolt threaded into an frail aluminum lever (cabrio top cable tensioner) that was hopelessly alloyed stuck together.

A day or two of Liquid Wrench and a couple cycles with the MAPP torch until the LW throughly smoked out and and it started turning with extreme care to support the lever.

the idea is expand the aluminum parts away from the iron without burning down anything else.

Still cant believe (and over joyed, as lever would be a super hard to find & worse to replace given the tiny blind-hole steel roll pin holding it into the main bow) it moved without fracturing the aluminum lever. lucky me

http://wd40.com/about-us/myths-legends-fun-facts/ ... naked burglar removal device

[John_AZ]

The usual end job is to remove the sensor bracket.
It is easier to remove the intake to get to the drivers side sensor bracket bolt head.
With the intake off you can do a lot of WYAIT items line AOS seals.

Another method is to smash the sensor bracket and hope you do not damage the engine block.

Just more interesting reading...
PRE Note: Cutting the bell housing as in the picture in the link may cause starter electromagnetic interference with the reference sensors. Hi Torque starters most at fault. YMMV.

http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/457162-my-new-944-reference-sensor-dillema-need-some-advice-porsche-gurus.html

GL
J_AZ

[Rasta Monsta]

+1 to John, as usual. Pull the bracket.

P.S. Cut my bellhousing with no ill effects, fwiw.

[mazdaverx7]

I had the same issue on my 85.5. I used WD40 sparingly and it was the key to removal. It lubricated the o-ring enough when twisting the sensor 180 degrees back and forth that it just slid right out. I would not remove the bracket as that will bean exercise in frustration in its own right. Use a lubricant sparingly and keep twisting and pulling upwards. Use pliers carefully if you intend to replace the sensor. They will give you a little extra twisting leverage. Take your time and be patient and it will come out.

[Marajit]

I slipped a large hose clamp under the sensor rubber part to gain better purchase, stood up on the engine and pulled like hell. They came off without any further drama.
Now I use anti-seize liberally before putting them back in.

[John_AZ]

Hi Rasta,

After I pulled the bracket I still could not get the sensor out. I cut the side and with force and penetrating oil it came out. The little black "O" ring can get hard and brittle.

Bought another & now I have a spare bracket.

[Slam]

After a couple hours trying to finesse these out of wifey's 87 I got bloody-minded and Mediaeval and took a BFH and a cold chisel to the bracket and just smashed it off the block. Brute force and ignorance won the day. Notched the bellhousing and reinstalled small-frame starter - no EMF troubles yet. I just didn't have the time to be all nice, you know? I agree with liberal antiseize on reinstall, even if you're not gonna be the poor bastard who tried to take them out next time.

[Toran]

Hello Everyone,

Thank you all for the speedy responses.

After a few hours I got it out. I stayed with it. I haven't cursed this much in years as I did this afternoon. And to be completely honest pulling that sensor to the left than right while pulling up was a #@$%&*! I felt it not only in my piano hands but in my shoulders, abs, legs. By the time it was out my body felt like it had been through boot camp!

You better believe I used some antiseize on the new sensor.

Thank you All again for the help and support

[Arizona_928]

I have acouple brackets with the sensors stuck in them because I didn't want to mess with getting them out.....
No real trick. just try not to break more then you can replace... ha