lambda sensor threads broke off in header/ DONE

[81SPIDERMATT]

man that thing was stuck and stuck good.... could not get it ... soaked it for hours and went back ... finally cut the wire -because it tested bad and was being replaced any way-- put a deep well socket and the breaker bar on it.... yeah..it is loose... NOPE... threads broke off of sensor and are still in the header.... no experience with this .... looking for direction..... hoping to resolve with it in the car.... its a 4 2 1 header on an 81 spider..... manifold bolts worry me a little.... the four holding down below the sensor to the next piece worry me a lot.... dont want to end up with more broken bolts if i have to take it out of the car to fix....... have removed all the stuff around it and have made myself a nice little work area.... key word little ... around the hole.... i can attach pics if needed ..... frustrated matt thanks you in advance for any and all help


and focodave if you see this... dammit.. missed the show... noticed it running a little rich and went thru the diagnostics... found a couple of things fixed and one last thing last night... o2 sensor...... aaaaaarrrrrhhhhhhggggggg

[81SPIDERMATT]

ok made the decision to remove exhaust manifold to repair .... manifold bolts all came out with no problem..... the four below the sensor.... PIA .... 2 snapped out of 4.... now i will 3 holes to fix ..... cant seem to break loose that connection ..... help ..h e l p .... HELP

[ORFORD2004]

Torch

[81SPIDERMATT]

HA HA ... there are 6 bolts.... found the hidden 5th bolt holding it on 6th bolt already snapped.... got it off .... with a punch methodically and slowly was able to remove threads from sensor hole.... now i am left with 3 studs about an inch long that i need to get out.... they are soaking and i am assuming vise grips and remove..... if they prove to be more difficult than i imagine... which they will .... please school me on torch usage ....never used one



what a pain for a sensor..... i better notice a difference

[focodave]

Matt,
Holy Crap!
It looks like you might get the old studs out with vice-grips and plenty of time soaking.
If not -- you may have to use a torch.
I, personally, am a fan of drilling out and tapping the holes but I guess that is because I don't own a torch.
I've used a torch plenty of times, 25 years ago at my parents' house in Maryland.
Don't worry.
Those studs WILL come out.
Dave

[narfire]

A couple of suggestions.... If you have enough thread, double nut and after heat try and back them out..

Not enough thread to double nut, file or grind two flat sides to the stud and try a crescent wrench or vise grips after a lot of heat...

If they break off again or just does not back out, try the welded nut trick. Heat from the welding can break the corrosion holding everything up.
http://www.fiatspider.com/f08/viewtopic ... ck#p165926

About halfway down are pics how I go about it.
Good luck
Chris

[81SPIDERMATT]

and we are heating the metal right.... not the bolt??? ... double nut.... wish i would have tried that first before vise grips..but only one bolt may have been long enough.... . how long is long for soaking......thanks for the link.... i have a welder ....

[81SPIDERMATT]

I, personally, am a fan of drilling out and tapping the holes but I guess that is because I don't own a torch.

that is funny.... i don't own the drills and taps

[ORFORD2004]

One trick that i saw on Overhaulin was to weld a nut over the stud and after that use a ratchet to remove.

[redcars]

My favorite method is to weld a nut on and then use that to turn out the broken stud. Go ahead and heat the manifold a lot first then let it cool, weld the nut on and let it cool. Welding on the nut heats the stud and as metal heats it expands, because the stud is in the manifold the only way it can expand is by getting longer. When it cools it gets smaller in diameter. If after doing a this and it breaks off I weld a thick washer on and use that to turn it. If all this fails then drill and tap. It does no good to get mad as parts have no fillings. Just take your time and you will get there.

[81SPIDERMATT]

soaking and waiting..... those stupid bolts ... i think you are right about them not having feelings.... no matter how much i cursed at them they still just sat there......... have a smoke... relax ... try again .... then heat .. more soaking... try again.... not gonna spend too much more time on it tonight.... if none of the three budge then tomorrow i will break out the welder

thanks for the tips ... stupid car

[81SPIDERMATT]

I AM THE BOLT MASTER




man do i feel better

[azruss]

before install of new studs, apply some anti-seize

[babu2001]

Just for others who will like to use torch. Just heat the bolt until it's a little bit glowing. Wait that it cools down because metal is softer when hot then give it a try. If the bolt still refuse to give, you blow now it at the base of the bolt. Both, case and bolt must be heated and dilated. When ready (depends on the torch, don't go too hot either, it doesn't need to glow and we don't want to melt anything), throw some water. Rapid contraction of the metal will break the rust bond especially when it's 2 different metals. Of course, don't do that on touchy parts like the head or you may warp it. Drill and tap...

[fiat218]

soaking and waiting..... those stupid bolts ... i think you are right about them not having feelings.... no matter how much i cursed at them they still just sat there......... have a smoke... relax ... try again .... then heat .. more soaking... try again.... not gonna spend too much more time on it tonight.... if none of the three budge then tomorrow i will break out the welder

thanks for the tips ... stupid car

First of all , stop smoking