stubborn o2 sensor

[aeb28]

I am having trouble with a stubborn o2 sensor on a 2004 v8 sr5.

The issue began with a CEL and computer throwing a P0031 Bank 1, sensor 1(o2 upstream, drivers side). For those of you who have had this issue, the sensor is accessible through the driver side wheel well slashguard. A few other threads on this forum address the issue (successful removal from those I found), I have stolen pics from them to show you what I am looking at:

Anyway, I tried lots and lots of Pen oil over the course of 24 hrs, and tried heating it, but still managed to round off the threads attempting to remove the sensor. I tried the electrical tape trick to no avail. It is too tight of a space for some vice grips. Also tried a pipe wrench, by the time it swings far enough to grip it has already hit. I recently moved and have pretty limited tools on hand, the rest are in storage on the other side of country. I am trying to avoid taking it to a shop if there is anything left I can do myself.

Any advice or options I have overlooked? I considered welding a socket, but I do not have a welder on hand. I have also considered pounding an undersized socket on, but I do not think there is room to do that either.

Thank you in advance.

Alex

 

[aeb28]

Bump... anybody?

 

[BlackWorksInc]

Ugh, that's a pain; can see those bolts are just toast.

Well I was going to suggest taking the steering shaft out so you get more swing OR removing the entire manifold to put it in a vise and get the O2 sensor out; but the damn bolts will probably fight you either way...

 

[fdbyrne]

Harbor Freight (and probably other places) sell crescent wrenches that are shaped like an 'S' that I have found helpful for those awkward spots. It doesn't look like the nut is completely rounded off. If it's not, get a set of those wrenches, find the best fit, cut off the other end, and slip a length of pipe over it for leverage.

 

[RaceTRaCk]

If the nut is still in good shape, get yourself a nice quality wrench. Maybe snap on if you can. Some wrenches flex open under torque and loses its grip. Or maybe use an oxygen sensor socket.

 

[Tyota89]

If the nut is still in good shape, get yourself a nice quality wrench. Maybe snap on if you can. Some wrenches flex open under torque and loses its grip. Or maybe use an oxygen sensor socket.

O2 sensor socket is what I suggest if you can get it in there. Snapon flex just like any other wrench. I use nothing but snapon all day at work. When a nut is tight, sitting in a jet engine exhaust I bring in the biggest crescent wrench I can find and tighten it down. Works every time.

 

[BOSMECH]

aerokroil ( Penetrating-Lubricating Oils ) and a O2 socket set.
end of story.
You can use the loan a tool at any auto store on the O2 socket set.

 

[aeb28]

Thank you for the replies, I will give it another shot with a good O2 socket. This thing is gonna be a PITA either way, in the mean time my gas milage will just have to remain in the toilet for a bit longer. I really hope it isn't too rounded off, otherwise I don't know what plan B will entail.

Also I tried calling a couple shops just to get a rough estimate of what the damage will be if I bring it to them... 2.1 hours seems to be the standard book time on labor. Thats insane, if it had gone smoothly it would have been a 10-20 min job.

 

[CruzadoBlanco]

wow i keep seeing these nightmare exhaust related posts and i feel so relieved with how mine went. i just soaked it in the PB for a couple of days and then used my big ass crescent wrench and it came out with little effort. i have found O2 sockets flex like mofos and just cause problems, but that may just be me. if you havent already check out kroil, its a miracle worker.

 

[aeb28]

wow i keep seeing these nightmare exhaust related posts and i feel so relieved with how mine went. i just soaked it in the PB for a couple of days and then used my big ass crescent wrench and it came out with little effort. i have found O2 sockets flex like mofos and just cause problems, but that may just be me. if you havent already check out kroil, its a miracle worker.

Yea I have heard mention of kroil a few times now on this forum, and its the one thing I havent tried that people seem to have a history of luck with. I gave WD-40 Pen oil a shot to no avail but I will give this a try along with a better wrench. Worst case I am out a few more bucks, the thought of going to a shop and paying them $200 bucks to pop it out makes my stomach turn. (That is unless I end up stripping or rounding it off completely, if they only charge $200 to deal with that its money well spent IMO. They said they charge 2 hours of labor no matter how long it takes them, shorter or longer)

 

[chompster4runner]

Do not use the o2 socket to remove it. It will flex and strip that nut. If you have a grinder, cut it in half and use a deep impact socket with extended pipe for leverage. Be careful not to bust your fender when it break loose. GoOD luck!

 

[aeb28]

Do not use the o2 socket to remove it. It will flex and strip that nut. If you have a grinder, cut it in half and use a deep impact socket with extended pipe for leverage. Be careful not to bust your fender when it break loose. GoOD luck!

What style grinder did you use to get in there? I contemplated a dremel but not sure if it could do the trick. I have seen where people on other vehicles have just grenaded it, they beat the hell out of it until it snapped off at the neck to get to it with a good solid socket. It is tricky to get anything much bigger than a wrench in there. I was looking at one of these from harbor freight that might do the trick and would be useful to have around in the future:
http://www.harborfreight.com/flexible-shaft-grinder-and-carver-40432.html

Anyway I will take your advice and order an deep impact socket.

edit: by "other vehicles" I meant other makes and models where the sensor placement is different and easy to get to.

 

[RaceTRaCk]

O2 sensor socket is what I suggest if you can get it in there. Snapon flex just like any other wrench. I use nothing but snapon all day at work. When a nut is tight, sitting in a jet engine exhaust I bring in the biggest crescent wrench I can find and tighten it down. Works every time.

Weird, I wasnt sold on snap on before until I used one. One time, my wrench kept slipping off and a fellow tech suggested I use his snap on and a couple yanks and it came out without a fuss. I still dont own any snap on stuff but I understand the value now.

 

[Tyota89]

Weird, I wasnt sold on snap on before until I used one. One time, my wrench kept slipping off and a fellow tech suggested I use his snap on and a couple yanks and it came out without a fuss. I still dont own any snap on stuff but I understand the value now.

I own a few snap on, kobalt, gear wrench.. Most of it is craftsman though. I have to say my gearwrench 120xp is one of the nicest ratchet I used.
All military buy is snap on, so I get a lot of hands on with them. They flex and break like any other wrench I used. Maybe a little less but not by much.

 

[chompster4runner]

So how did it go? Out camping up the mountain with no signals. Breaking the o2 sensor is not hard.

 

[aeb28]

So how did it go? Out camping up the mountain with no signals. Breaking the o2 sensor is not hard.

Wrenches flexed an began rounding it off so I stopped while I was ahead. I ordered some kroil and a grinder that can get in there to cut off the sensor body so I can get to it with an impact socket that wont flex with a breaker bar.

Yes in theory breaking the o2 sensor is not hard. Though I am not done with it yet, this one is proving to be a real a**hole. Stuff should get here next week and I can get after it again. Thank god I do not have a lift, I am probably getting 8 mpg right now around town and I can smell the fumes driving down the road with back windows open. Hope my cat converters haven't pooped out on me.

environment:gun5:

 

[chompster4runner]

I hear ya. Keep trying when the manifold is super hot from driving. In theory it should expand the manifold a bit but the o2 sensor would too..

Wrenches flexed an began rounding it off so I stopped while I was ahead. I ordered some kroil and a grinder that can get in there to cut off the sensor body so I can get to it with an impact socket that wont flex with a breaker bar.

Yes in theory breaking the o2 sensor is not hard. Though I am not done with it yet, this one is proving to be a real a**hole. Stuff should get here next week and I can get after it again. Thank god I do not have a lift, I am probably getting 8 mpg right now around town and I can smell the fumes driving down the road with back windows open. Hope my cat converters haven't pooped out on me.

environment:gun5:

 

[aeb28]

New grinder came in this afternoon, looks like probably tomorrow I can knock this stupid thing out. While I have been waiting I have been spraying it with kroil when I park it in the evening for it to soak in overnight. I have a deep wall impact socket with a 1/2" drive 24" breaker bar. If that doesn't do it I don't know what will.

 

[aeb28]

update

Finally got around to posting the results. This is what worked:

-Several kroil treatments

-cut sensor in half so it can be fitted with a deep socket

- pounded on a 22mm deep impact wrench socket, rounded corners corrected themselves

-24" breaker bar broke it loose

-Success! Right tools for the right job.

Thank you guys for all of your input.
Right tools for the right job.