Well that sounds strange.... What started as an easy FA Sensor replacement (rear one) has turned bad. The sensor was very had to get out, I used penetrating oil and even started the car to get it hot and it eventually came out, but.... the threads in the bung on the manifold are now stripped. So what are my options? Chase with a tap, new manifold, weld in new bung? ...This is our only car and I have to drive it, that's going to suck.. ....any advice?
...anyone know the size and pitch of the threads or which tap I could use?

 

Without seeing a picture of it (and trying to imagine this in my mind), I would say a new bung. I could probably jury rig it some other way if I saw a photo of it.

 

I'll post a pic in a few min.

Thanks

 

OK, I will check it when I get home in about an hour from now.

BTW, though I live in Mexico, I am a native Floridian (have Florida plates)

 

 

Threads dont look too bad.

I would try re-tapping with the orignal threads and toque in the piece very carefully.

Other options:
Bore out 3mm higher and JB Weld followed by re-tapping. [JB weld and re-tap would not work as there will be very little material to bond with metal.

Cut threads 6mm higher and have a threaded sleve insert.

Helicoil.

Salim

 

Do you know if this is a standard 18mm bung? I was thinking of taping it or using a 18mm thread chaser.

 

I agree.

Not as bad as I thought either.

 

So do you know if it is fact 18mm?

 

18 mm should do the job, however I have never measured it nor have I seen a listing in the manual (I just checked for you)...but the photo I see and from what I remember looking it at last time at my exhaust shop that LOOKS about right.

 

As others have noted these threads don't look bad at all from the picture. Before doing anything else, determine the diameter and thread pitch of the sensor (i.e. 18mm x 1.4). Get the correct diameter and pitch tap and re tap the threads. Install the sensor using copper based anti-seize and carefully install the sensor. If you want to torque it, I would set the torque wrench at 20 % below noted value (to compensate for anti-seize lubrication). If the retap doesn't hold, then go to Napa and get a Heli-Coil oxygen sensor thread repair set such as this,

http://www.thetoolwarehouse.net/shop/HEL-4833.html

which will have the tap and threaded insert necessary to open up the hole and insert a threaded sleeve which brings it back to OEM size. Good luck.

 

thanks guys for all your help. I'll update tomorrow how things worked out.