O2 sensor hole repair

[TominMO]

Took off the O2 sensor in my newer-to-me Aspire SE (not yours Arty), to replace the cheapo sensor with a new Denso one, and discovered that the hole for the O2 sensor is stripped out. Very little thread showing. What's the best way to repair that hole? I'm thinking helicoil, but the kits I have seen online are $80 - $129! :eeeeeek: These kits do come with 5 or 6 helicoils tho; probably a lifetime supply for me. Old sensor was rusted in; no antiseize was used, naturally.

My previous Aspire, which Arty is buying, has been the cleaner car; I don't think it got much winter driving (we salt the roads here). It seems to have been better kept up too.

This one was obviously driven through the winters here, and replacement parts installed were low-grade. PO (a young woman) was overcharged hugely for at least some of this, according to the repair records I got with the car ($100 each for cheap inner and outer tie rods). So I am in the process of putting it right, with top-quality parts. I did the front brakes, and the old rotors were rusty peices of junk! Never seen any this bad.

So anyway, back to the O2 sensor hole issue. Any other thoughts besides helicoils?

EDIT: I might be able to get by with a thread chaser made specifically for the O2 sensor hole. Saw one online for $5. The threads look worn down, but not completely missing.

http://www.toolsource.com/oxygen-sensor-thread-chaser-p-97038.html?osCsid=m9qpubn3mndc1g0n24qbk5bdv4

It's even available at Amazon! And Sears.

[georgeb]

It doesn't have to be that tight. I would try it as is.

[Basement_Modder]

If it won't thread in as is, and the $5 cleaner doesn't work, than I'd recommend:

A- boring it out as big as you can, welding a new "ring" spacer in, and threading that
B- helicoil thing mentioned earlier
C- new manifold off scrap car with good threads

[htchbck]

I would go with georgeb's recommendation first, and if that doesn't work I prefer the idea of finding a manifold. I'm sure someone here has one you can get for a lot cheaper than that helicoil kit. I have a couple of festiva ones laying around, but no Aspire for you unfortunately.

[FestYboy]

tom, they do make a thread chaser for that application. but it depends if the threads came off the sensor or pulled out of the bung. the chaser is only good if threads are off the sensor (which meand the threads in the bung are still intact).

[TominMO]

It doesn't have to be that tight. I would try it as is.

Threads are too worn; sensor won't tighten down.

If it won't thread in as is, and the $5 cleaner doesn't work, than I'd recommend:

A- boring it out as big as you can, welding a new "ring" spacer in, and threading that
B- helicoil thing mentioned earlier
C- new manifold off scrap car with good threads

I thought of all these too. I was thinking of finding a Festy manifold, since I heard they flow better. But for confirmation, will a Festy EFI exhaust manifold work on an Aspire?

tom, they do make a thread chaser for that application. but it depends if the threads came off the sensor or pulled out of the bung. the chaser is only good if threads are off the sensor (which meand the threads in the bung are still intact).

The link in my edit is the thread chaser. That is the simplest solution, but I am not sure if there is enough thread left for it to work. There are threads in there, they just look worn down; probably cross-threaded. I'll find out when I get the chaser/tap. My Plan B is either getting a used manifold or the helicoil kit.

[MasterTec]

If it screws all the way down but won't tighten (just spins) then a thread chaser isn't going to help as there simply isn't enough metal left.

Your three options are:

-Replacement manifold
-Helicoil
-Weld on a new bung

It may be possible to simply weld a new one over the old one without having to cut a hole in the manifold. You might be able to find a local exhaust shop that could do this for $20-30 or so.

[nitrofarm]

Can JB weld withstand that high temp? Thats a fast way to fix it.
Otherwise get a new bung.Remove the header.Grind off the old bung.Take the header & bung to a exhaust shop.They should weld it for $20.00. Done-
edit LOL I type to slows master tec !

[Movin]

Jb good stuff but not where something may need a ground path.
With HHO I have welded the replacement bungs over the the original
bung to slightly lean the mixture..O2 tends to swirl in the center of the
exhaust flow. You should not encounter any problems with over-lean
burning, these cars are not usually on the lean edge of things.

also, a spark plug chaser is the same thread.

[georgeb]

How about welding the sensor to the bung with a spot weld or two? It's not the space shuttle.

[nonamekid]

...will a Festy EFI exhaust manifold work on an Aspire?

Yes. You may want the downpipe also, as I believe that is different between the 2 cars. I have friend running an aspire engine in his festiva with the aspire manifold and aspire downpipe and it bolted up just fine.

[Movin]

How about welding the sensor to the bung with a spot weld or two? It's not the space shuttle.

As some one who would not do this while at home I would say not a good
option, but if stuck in Mexico I would unplug the sensor and do as you
suggest to get home. Another option is possibly the brand new threads
of a spark plug would hold until home, but I think this OP could not get
brand new threads of a new sensor to hold. Even a wrap or two of that
muffler repair kit stuff would hold the sensor in place.
^^ unplug for welding then plug back in, or drive with check
engine light on.

[georgeb]

Why would you have to unplug it? Would the spot weld ruin the sensor? Also how about welding a bead through the threads of the bung and running a tap throught it.

[FestYboy]

you dont want 30-80 amps running through the sensor using the wire as an alternate ground.... tends to burn things up. you also don't want to weld on the sensor as it's not designed for that much heat and will ruin it.

tom you'd need both the festy manifold AND the downpipe if you wanted to go that route.

[TominMO]

Tried the thread chaser. Bought at Advance; has 18x1.5 on one end (O2 sensor) and 14x1.0? on the other end (spark plug). As I suspected/expected, not enuf thread for it to grab onto. Prefer not to go the Festy manifold route, due to having just fabbed up a complete exhaust for the car, based on the Aspire downpipe! Plus hunting around in the JY for a suitable candidate. Might find a good Aspire manifold tho. That's plan A.

Plan B is to have a new bung welded onto this manifold--maybe open the hole up enuf so it can be inserted in place of the old bung. Either way I need to pull this mani and buy new gaskets for whatever one I use.