o2 sensor stud

[ktmracer01]

Ok...where to begin...? Decided to change my O2's on my 1994 cruiser and on my way back from the local Sears store with new nut extractors, my 1992 FJ80 overheated due to a failed water pump and 112 degree weather yesterday, my rad cap failed and caused the 20+ year old top plastic radiator cap to split.... had to get towed home.

with tools in hand I decided to tackle the 1994's O2 sensor while my 1992 was cooling down. I had been lubricating the O2 sensor studs for several days prior in anticipation of pure hell and frustration getting the rounded/ rusted nuts off ( thanks to the un-named dealership that said they changed both out about 10 years ago). one you could tell had been replaced, the other still had the factory rubberized undercoating sprayed all over the electrical connector when it was new and after seeing how rounded the nuts were, a serious attempt had been made before the tech decided to give up.

now after my rant and rave here, I finally got the old O2 sensor out thanks to all of the threads on what nut extractors to purchase. and when I was putting in the new O2, I got one nut snug and went to snug the other side and the stud snapped off...

where can I source a new stud? my local parts guy at the stealership here said he can't source the studs. so I check slee's website and they're out of stock, then my next option was SOR, they didn't have the parts listed on their website either; any suggestions on where to get a new stud? I'm anticipating taking out the cat and the header to extract the broken off stud. Maybe just drill the old stud out and re-tap it and thread in a bolt from the top? If I can't get this all figured out, I may decide to take it to an exhaust shop to have them extract it, or even weld in a new bung and put in different studs.

Any suggestions welcome at this time.

 

[Tenzig Norgay]

Clamp it real tight, and tack it on with a welder? May just do the trick, and can be undone if careful.

 

[ktmracer01]

never thought about that, will be taken into consideration as a temporary fix until I can get it fixed properly.

 

[ktmracer01]

here's a couple pictures

 

[ktmracer01]

a couple of the rounded nuts that I had to take off

 

[ktmracer01]

one of the broken off nut with the two that were rounded off. notice, the second photo, you can see where it had rusted more than half way through. it's no wonder it twisted off with ease.

 

[Bogart]

Studs

I had a similar problem and I went to the hardware store and bought some M8 by 1.25 bolts, threaded on the nuts then inserted the bolt into the Bung till tight, then tightened down the nut on top of the O2 sensor flange, worked like a charm.
On another vehicle I snapped of a stud and used permatex as a temp fix adhesive and one stud / nut combo, still holding several years later
Hope that helps

Cheers Peter

 

[alby_39]

Do you guys ever think outside the box? Go to your local stealership and get them for say a Camry, Hilux or anything Toyota. Also dont go for steel/cast nuts, go for brass nuts. They dont seem to destroy the thread as the genuine nuts do. My 2 cents

 

[Pin_Head]

Weld a nut on to the remains of the broken stud and then just turn it out after it cools a bit. Works great on busted exhaust studs.

 

[sleeoffroad]

you can try a wheel hub stud or a fan hub stud. Simple m8 stud.

 

[ktmracer01]

Thanks for the input everyone. will look in to sourcing the new stud. I imagine that this afternoon I will be welding a nut to the end of the stud to extract, then sourcing a hub or fan stud to put in its place.

thank you everyone. will let you all know how it goes.

 

[revelario]

Thanks for the input everyone. will look in to sourcing the new stud. I imagine that this afternoon I will be welding a nut to the end of the stud to extract, then sourcing a hub or fan stud to put in its place.

thank you everyone. will let you all know how it goes.

How did it go?