Advice for a broken O2 sensor bolt?

Was finishing up replacing my downstream sensor and thought I'd force the nut in.. ended up causing what's show in the picture

Am I screwed?

 

you might be able to cut it flush, and drill/tap it for a bolt.

Or try and find a section of pipe with the sensor mount at a pick-n-pull and splice in that piece and weld it up, or just use some of those couplers.

 

Exhaust shop could burn another one on for you pretty quickly

 

Easy peasy for an exhaust guy...had that twice on my 99 4Runner, fore and aft cat. Rip replace bolt and put it back in

 

I had the same thing happen and was able to get it out using mini vice grips after heating with torch, soaking in liquid wrench and a few good taps with a hammer. I ran a 8mm x 1.25 tap in to clean the threads before replacing with a new stud. Thought I was screwed too before that.

 

Aw man. That's so good to hear. I'll be doing this first. If all else fails.. I'll take it to a muffler shop like others have recommended

 

Good idea. I'm thinking it'll be a pain in the A doing so with the limited space there

 

That's about the same lil bit of stud as I had left to work with. The longer you let penetrating oil soaked and reapply the better. I heated, let cool, soaked, hit it, heated it again and soaked more over a couple of days. Popped right out though.

 

Did you use a new bolt or did you find a screw that fit?

 

I bought new nuts and bolts at Advance Auto. Had to put a nut on the bolt and cut the bolt head off then back the nut over the cut end to make sure it would thread ok. Couldn't find the exact stud replacement

 

Alright. I'm thinking if the bolt is able to screw out, I can maybe find a stand alone screw that fits, to use instead

 

The size is 8mm x 1.25
The O2 studs are available but were sold out at the time.
Get some anti seize too.
You'll have to lock two nuts on the new stud to wrench on when installing the new stud.

 

Thanks so much for the info! Will update this thread soon

 

I no longer mess with even trying to fix these.

Cut the old bung off install new one new studs by far the fastest and easy way for me

years ago I wasted the best part of 4 hours no more bungs and studs on the shelf.

 

Like Wyoming above, I no longer mess with trying to fix this type of issue either. $35 for a new Walker intermediate pipe from Summitracing.com when I replaced my muffler worked just great. i will say that both my sensor mount bolts were much worse than the OP - there was no way I was getting either nut off due to rust on the threads.

 

OEM studs are available for $3: https://parts.lakelandtoyota.com/p/__/BOLT--STUDFOR-OXYGEN-SENSOR/4093979/9012608001.html

You can file down the stud sides into a square and get a wrench around it to get it out. I had to do that to the nuts on the O2 sensors as they were completely rusted round.

You can use the "2 nut" trick to get the bolt back into place.

 

sounds like a good idea, but I would have to have a welding machine already

 

For my 2001 3.4L, it was all bolt on - is your 2002 2.7 different? I’m genuinely curious...

 

How to get the stud back in: 16:50

https://www.youtube.com/watch?v=nFYEoWTX0YU

 

Wish the stud was longer so I could do this. I think only one nut is able to screw in. I soaked it in PB Blaster overnight, and tried to unscrew it with some pliers, but no luck..
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Though, with the stud being broken off at a length so that it's flush with the O2 sensor & gasket (pic #1).. I then used one of the HVAC screw clamps I had lying around to tighten it (pic #2). Waiting until Monday to take it to a mufflershop, so they can get it out for me