Cars - Advice for stripped threads upstream oxygen sensor exhaust manifold

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Arlen Holder

August 2nd 18 04:31 AM

Advice for stripped threads upstream oxygen sensor exhaust manifold

Paul in Houston TX[_2_]

August 2nd 18 05:25 AM

Advice for stripped threads upstream oxygen sensor exhaust manifold

Arlen Holder wrote:
> Car is just bought by a kid just learning to drive (he's 16).
> 2004 Mitsubishi Lancer ES
>
> Neighbors asked me to teach him how to replace the oxygen sensor (due to
> emissions code).
>
> The threads were stripped and "filled" with some kind of hardened "metal
> paste".
>
> The new part is a Denso 234-4739 (marked 485000-4060, 07U05)
> The old part is a Denso (marked 234000, 8643, 07E23)
>
> What would you suggest?
> - Tap the threads? (22mm hex nut)
> - New exhaust manifold?

IF it were my car and IF the manifold is steel, I would remove the manifold,
then remove the square nut, and weld or braze in a thin-ish nut of appropriate
thread size.
If no thin-ish nut is available then make one with the dremel.
The sensor needs to be in the flame and also have good thermal conductivity to
the manifold.

Bob F

August 2nd 18 05:41 AM

Advice for stripped threads upstream oxygen sensor exhaustmanifold

On 8/1/2018 8:31 PM, Arlen Holder wrote:
> Car is just bought by a kid just learning to drive (he's 16).
> 2004 Mitsubishi Lancer ES
>
> Neighbors asked me to teach him how to replace the oxygen sensor (due to
> emissions code).
>
> The threads were stripped and "filled" with some kind of hardened "metal
> paste".
>
> The new part is a Denso 234-4739 (marked 485000-4060, 07U05)
> The old part is a Denso (marked 234000, 8643, 07E23)
>
> What would you suggest?
> - Tap the threads? (22mm hex nut)
> - New exhaust manifold?
>
> http://www.bild.me/bild.php?file=3234632o2sensor01.jpg
> http://www.bild.me/bild.php?file=8064061o2sensor02.jpg
> http://www.bild.me/bild.php?file=6399144o2sensor03.jpg
> http://www.bild.me/bild.php?file=1574232o2sensor04.jpg
> http://www.bild.me/bild.php?file=9418974o2sensor05.jpg
> http://www.bild.me/bild.php?file=4183674o2sensor06.jpg
> http://www.bild.me/bild.php?file=5856176o2sensor07.jpg
> http://www.bild.me/bild.php?file=3486734o2sensor08.jpg
> http://www.bild.me/bild.php?file=9694112o2sensor09.jpg
> http://www.bild.me/bild.php?file=5019152o2sensor10.jpg
>
I'm no expert on this particular situation, but perhaps a helicoil would
solve it easily.

rbowman

August 2nd 18 06:26 AM

Advice for stripped threads upstream oxygen sensor exhaustmanifold

On 08/01/2018 09:31 PM, Arlen Holder wrote:
> What would you suggest?
> - Tap the threads? (22mm hex nut)
> - New exhaust manifold?

Back to your friendly Loctite dealer for the Form-A-Thread kit? Trip to
a junkyard for a new manifold if replacing it isn't too painful? Helicoils?

Arlen Holder

August 2nd 18 06:36 AM

Advice for stripped threads upstream oxygen sensor exhaust manifold

On 1 Aug 2018 21:25:57 GMT, Paul in Houston TX wrote:

> IF it were my car and IF the manifold is steel, I would remove the manifold,
> then remove the square nut, and weld or braze in a thin-ish nut of appropriate
> thread size.
> If no thin-ish nut is available then make one with the dremel.
> The sensor needs to be in the flame and also have good thermal conductivity to
> the manifold.

I had not thought of putting a new nut on.
I'll look in the morning to see if the nut is the only threads.
I'm sure the sensor has to be "in" the stream of hot vapors.

It seems to be cast iron. Aren't they all that way?
(It's rusty.)

Arlen Holder

August 2nd 18 06:37 AM

Advice for stripped threads upstream oxygen sensor exhaust manifold

On 1 Aug 2018 21:41:29 GMT, Bob F wrote:

> I'm no expert on this particular situation, but perhaps a helicoil would
> solve it easily.

I guess it can't hurt.
I can contact Denso to figure out the thread pitch for their O2 sensors.

I was thinking of cleaning up the threads, but they look really bad.
How on earth can ANYONE do that to a bunch of threads?

What did they do?
It's not even hard to get to ... it's right there ... in front.

Arlen Holder

August 2nd 18 06:39 AM

Advice for stripped threads upstream oxygen sensor exhaust manifold

On 1 Aug 2018 22:26:00 GMT, rbowman wrote:

> Back to your friendly Loctite dealer for the Form-A-Thread kit? Trip to
> a junkyard for a new manifold if replacing it isn't too painful? Helicoils?

Seems to me the choices are...
a. New or used manifold (if it's not too hard to replace)
b. Drill it out and helicoil it (nothing to lose really)
c. Clean it up with a tap (I don't have the tap, which won't be cheap)
d. Shove it in there with epoxy (I hate that idea so I don't want to)

Arlen Holder

August 2nd 18 07:18 AM

Advice for stripped threads upstream oxygen sensor exhaust manifold

On 2 Aug 2018 05:39:22 GMT, Arlen Holder wrote:

> b. Drill it out and helicoil it (nothing to lose really)

Googling, I'm not yet sure a helicoil will work on a through hole.

I think all lambda sensors are 18x1.5 (I'm not sure, but people said that
on the net). Some say it's the same thread as for spark plugs.

If it's the same as for spark plugs, this might work, maybe?
https://shop.advanceautoparts.com/p/...2002/5014964-P

Napa seems to sell a thread chaser for spark plugs, if it's the same thread
as spark plugs...
https://www.napaonline.com/en/p/SER730

This bung might be able to be welded on by a shop if the threads are right:
https://www.diyautotune.com/product/...plug-kit-3735/

The manifold is almost five hundred bucks
https://www.carid.com/eastern-cataly...46&url=4700416

Steve W.[_6_]

August 2nd 18 07:30 AM

Advice for stripped threads upstream oxygen sensor exhaust manifold

Arlen Holder wrote:
> On 2 Aug 2018 05:39:22 GMT, Arlen Holder wrote:
>
>> b. Drill it out and helicoil it (nothing to lose really)
>
> Googling, I'm not yet sure a helicoil will work on a through hole.
>
> I think all lambda sensors are 18x1.5 (I'm not sure, but people said that
> on the net). Some say it's the same thread as for spark plugs.
>
> If it's the same as for spark plugs, this might work, maybe?
> https://shop.advanceautoparts.com/p/...2002/5014964-P
>
> Napa seems to sell a thread chaser for spark plugs, if it's the same thread
> as spark plugs...
> https://www.napaonline.com/en/p/SER730
>
> This bung might be able to be welded on by a shop if the threads are right:
> https://www.diyautotune.com/product/...plug-kit-3735/
>
> The manifold is almost five hundred bucks
> https://www.carid.com/eastern-cataly...46&url=4700416

Same threads as a spark plug. The easy repair is a plug rethread kit. It
has an oversized insert with a self guiding fluted cutter/tap
combination. Then you trim the threads on an insert so they don't block
the sensor tip. Screw it into place and screw in the sensor. About the
third time you drive the car that insert will become a permanent part of
the manifold.

Very common repair, done all the time.

--
Steve W.

Arlen Holder

August 2nd 18 07:44 AM

Advice for stripped threads upstream oxygen sensor exhaust manifold

On 1 Aug 2018 23:30:57 GMT, Steve W. wrote:

> Same threads as a spark plug. The easy repair is a plug rethread kit. It
> has an oversized insert with a self guiding fluted cutter/tap
> combination. Then you trim the threads on an insert so they don't block
> the sensor tip. Screw it into place and screw in the sensor. About the
> third time you drive the car that insert will become a permanent part of
> the manifold.
>
> Very common repair, done all the time.

Thanks for confirming it's the same threads as a spark plug, which, at the
moment, seem to be 18x1.5 for them.

Googling, it seems cast iron isn't easy to weld, and that the plug rethread
might work, but, the heat cycling has likely hardened the bung nut, such
that it's a LOT harder (some say) to deal with than a spark plug thread
which is typically in aluminum engine blocks (they say).

Searching for this "plug rethread kit", is this the $62 kit you speak of?
https://www.amazon.com/Thread-Kits-1.../dp/B0025PQITU

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