I had an elective O2 sensor replacement that quickly got out of hand. It worked, only occasionally there was a stumble in the idle and Torque would show the Bank 1 sensor not sending any info.
Knowing it was a 20 year old sensor, I still managed to under estimate the challenge.
Five days of constant penetrant sprays
One bottle of propane
Two O2 sensor wrenches
Three broken hose clamps to shore up the O2 sensor wrenches
Pipe wrench, channel locks, vice grips, impact sockets, 30" of extensions

It was simply galled into place. The technique of going a few degrees and reverse and forward with spray seemed to make the difference. But who can tell after all the chemicals, heat and brute force what really did the trick.

I finally go it out. Definitely cut the wires once you decide to replace it, much easier. I even dropped the exhaust gain some room. Amazingly none of those bolts snapped.

I need to learn to leave well enough alone.



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I feel you, I have one coming up that I will need to do. Which Penetrant did you use, Aerokroil is the best by long ways in my opinion for these situations. My patience is much shorter than yours though, I am already considering having the muffler shop weld in a bung.

 

I used aerokroil and a silver can, I forget the name. It's better than PB blaster. Knowing what I know, I would just cut it w a grinder and use an impact from above. Atleast to loose. It enough to get some penetrant in there. It could gall the threads if you used the impact to remove it all together.

I had no threads left on the sensor but luckily the exhaust was fine.

 

Pulled headliner, resealed sunroofs, fixed drains (one completely snapped off).
Still leaking above windshield. Found one more possible cause…and I didn’t think I had any rust !

 

 

What was your clue that the flex plate had issues? I’m a bit suspicious of mine in the P38, as I have a slight vibration that is sometimes there. It’s RPM related, not vehicle speed, and it seems to disappear on torque converter lock up.

 

No symptoms until it sheered and then didn't have any drive.

 

That sucks! Happened to my dad when he was pulling a boat, same area came apart! Hope you got home safe after that

 

Ok thanks. My vibration isn’t enough for me to tear things apart to look without a bit more of a definitive reason. It’s just not as smooth as the Disco. ​​​​​

 

Digging the seats, where did you get those?