How To Remove A Stuck O2 Sensor When Everything Else Has Failed

Procedure for removing a stuck O2 sensor when all other methods have failed.

[@kilts4u2]

This looks like the way I'm going to have to use on my '85 Camaro. None of the traditional methods recommended have worked. Penetrating oil. Fire. And yes, I've rounded the edges on the sensor even though I did my very best not to. I'd like to remove this sensor instead of welding a bung into the existing unit. The biggest problem, outside of not wanting to come out, is--the damn car sits so low on the ground to start with. I don't have a lift. As a remodeler on kitchens and baths, I've used the drill method on lots of plumbing problems. Now it's time to try it here. Nice video. Well presented.

[@gsgarage2462]

Could try some 2x4s or thinner to ease it up onto a set of ramps if you haven't thought of that to get it high enough to work under it. Thanks and good luck!

[@baybilla1985]

I just had the same problem. You wouldn't believe what I used. A little heat and a pipe wrench smh. Have to keep one of those handy. Lifesaver!

[@gsgarage2462]

Glad it worked out. I also tried heat, but with a vice grip with no luck.

[@GadGetHackss]

I usually just cut the wire and use a deep socket with a very long breaker bar, works every time

[@frankdahlquist1851]

Will be trying your method if I can't get my O2 sensor out. Thanks a lot!!!

[@GadGetHackss]

​@@frankdahlquist1851Yeah hopefully it works for you.. Also heat it with a flame gun

[@frankdahlquist1851]

@@GadGetHackss thanks for the reply. I don't have one yet.

[@PainterD54]

I'm at that point of removing my 02 sensor and I've tried everything, even welding a bolt onto the nut part of the sensor. That just broke off the remaining part of the nut, so I'm at the point of the remainder of it being flush with the bung. I soaked it with PB Blaster and used heat and a socket to remove the sensor, but it just took the corners of the nut right off. The tried the pipe wrench trick and it pretty much rounded off the remainder of the nut portion. Then I welded a bolt to the what was left of it, but that just took the rest of it off! Now I'm left with almost nothing - almost flush to the bung with a few jagged edges sticking out!! I may drill it and see if I can do like you did, or last resort, weld in a new bung alongside of the old one. Atleast I don't feel so bad knowing I'm not the only one that this happened to. Thanks!

[@ZBrink11]

I'm in the same place as you and took the exact same steps to get here 🙃

[@davycrockett4395]

Im on day 3 now my next step is bolt extractor if that fails then this.

[@anthonsama4786]

unfortunately i am in this exact situation, something that was supposed to take 10 minutes now its taking 2 days, thanks for the video, that's my only option now.

[@gsgarage2462]

Good luck and thanks for watching.

[@mumbles552]

Glad I'm not the only one with this problem! Had to do the same thing on my '96 Ford F 150 with original sensors. One manifold had to be removed and I cut the exhaust pipes out to install a new cat and O2 sensor.

[@gsgarage2462]

Glad it worked out

[@emersonc6443]

I'm just gonna replace my downpipe with something newer and bigger, fuck this😂

[@rogervind2450]

Thanks for the funny commentary, it really lightened my O2 frustrations! Hacksaw, you're a beast... But seriously thank you for the detailed and helpful explanation 👍

[@alexvagias5295]

This is good stuff. I never thought of this option. Thank you.

[@josephwood499]

I have a sensor on my old toyota that is stuck like concrete. The bad thing is that there is barely room to get one hand in there and need to change because the car is running like crap

[@jjyemg2397]

Love these great hacker videos!!!

[@ciarannaughton3274]

use left fluted drills for extracting threaded ends

[@billwilson6096]

Thanks for the good tutorial.

[@ryancornelius1007]

Well this where I am. I’ve tried everything. Vehicle only has a hundred thousand. Crazy it’s this stuck. Looks like I’m cutting the mounting hardware and going this route. I’m so frustrated.

[@gsgarage2462]

Cutting off hex and drilling out hasn't worked? If so, the only option is to cut out the old bung and weld in a new one.

[@ryancornelius1007]

mine is still froze in, ive got to cut it and drill it out and try and tap the threads out like you showed. just havent had the time to get it done. going to try and do it saturday. dreading dropping the exhaust lol.

[@MoSportsUSA]

I seriously don't know why cat mfrs don't apply anti-seize on O2 sensors at the factory. It's not like these aren't historic for welding themselves in place over time.

[@RededicateYrLife]

No wonder why they charge alot anything related to manifolds replacement because they know the time consuming this can be with everything heated and rusted on with good chances of braking the head of an old stubborn bolts

[@gsgarage2462]

Precisely

[@dfields9511]

This scares me . As i am about to change b2s2 on a 20 year old 2001 maxima. Looks like it’s the original sensor . Hopefully it doesn’t come to this.

[@frankdahlquist1851]

Oh please God! I hope i don't have to do this cause mine won't come out!!!

[@FahimMotoGP]

automotive design failure

[@gsgarage2462]

Agreed