How Would You Remove This Oxygen Sensor?

This corrosion is so severe that I can't even see a nut. How would you attack this?

 

I’d pound a external bolt remover on to the studs and try and remove the stud and nut at the same time

 

Probably want to use a lot of PB Blaster.

They make sockets for removing rounded bolts.

You can also try cutting a slot in the bolt with a Dremel and then use an impact screwdriver with a flat bit.

You could also sawzall the thing under the head of the bolt, slide off the remaining portion and then use some vice grips to work out the remaining screw.

If you can weld you could tack a nut to the top of the bolt and remove them that way.

 

Mine looked the same. I beat on a smaller socket

 

https://youtu.be/0N2sIZeufrc?si=RX2ezvDF5yghUHgg

 

b4 you do anything.....
i would just make sure that you cant feel an exhaust gas leak here:

 

How do I test this?

 

It's important to know that the studs are threaded into the bung on the exhaust. They are replaceable if you damage them. That being said- if it were me, I wouldn't think twice about getting in there with a cut off wheel and do some precision cutting on whats left of the bolts, and then just replace the studs.

 

Start it up. Put your hand down there and feel.
I'd be surprised if you got that off without snapping a post. Then you just created a bigger problem.

Like mentioned above...a leaking exhaust could read as a bad O2 sensor.

 

Become friends with someone who has a torch and a welder. Good luck!

 

what bkhlr says^^^^^

as long as truck/exhaust not volcano hot can use soapy water in spray bottle too

 

Smoke machine through the tailpipe, would that work to locate any leak?

 

It would.

 

PB sprays over a day, a map gas torch, and it will come right off. Heat it, let it cool, and do it again if it fights. Worst case Dremel the nuts off and deal with the studs.

 

I second cutting/grinding the nuts off and then using vice grips to remove the studs and replace them. Its gonna be rough/hard/dirty work. PB blaster will absolutely be your friend here.

 

IF no exhaust leak found
I would carefully use dremmel and make slot in what is left of those bolts(not dmging stud threads)
Then use flathead/hammer and split bolt
This also depends on clearance u have

if there is exhaust leak on the base of O2 sensor…..
I would just take to exhaust/muffler shop
They likely would just section in a pipe along with new O2 bung with studs
That O2 bung is universal (just like the newer style ones (only a threaded bolt)
$200 at the most

 

I would probably try using a nut splitter first. There are sets in the $20-30 range on Amazon. If that didn’t work, I’d probably try using a bolt/nut extractor socket. If you can remove the nut without damaging the stud you’ll save yourself some time, but there’s a good chance they’ll come out together.

 

Went through this on both front and back O2 sensors. Use a small file to file down one side of the nut off. Then tear the nut off with needle nose pliers. But your gonna need to replace that section of pipe/muffler soon. Had the same issue and replaced the muffler, O2 sensor and hardware at the same time while it was out.

 

that is a California rig?

 

Mine looked like that. I just heated the nut residue red hot with a hand torch and then unscrewed the nut using channel locks.