Danny Beardsley wrote:
> In the process of trying to replace my O2 (Oxygen) sensor on my 1993
> honda civic EX, I broke the old one off. I tried some usual stuff,
> knocking it with a hammer, liberal WD-40, running the car for a bit to
> heat up the manifold. Anyway, TINK! it broke. Any suggestions?
>
> Two pictures of the sensor and manifold
> http://img416.imageshack.us/my.php?i...anifold7eh.jpg
> http://img416.imageshack.us/my.php?i...2sensor9it.jpg
>

First of all, WD-40 is not a penetrating oil, claims to the contrary by
the manufacturer and thousands of users notwithstanding. It's a little
late now, but really, you should have used Kroil, PB Blaster, or one of
the other purpose-made penetrating oils rather than WD-40. Guess you
will remember that next time :/

Now as to your immediate situation - that sucker is broken off in a very
difficult way. I would personally suggest, if you have access, dropping
the downpipe so the bottom of the manifold is open, and then trying to
drill it out with successively larger drill bits. If you are lucky the
drill bit will "catch" and spin the remaining piece out into the
manifold (this is why I suggested dropping the downpipe.) If you are
less than lucky, you'll end up drilling it out to the threads, in which
case a spark plug thread chaser tap should clean them up.

You may find it easier to remove the manifold from the car; I haven't
ever worked on a Honda so I don't know how difficult access is vs.
manifold removal.

Needless to say, put some anti-seize on the threads of the new O2
sensor, and next time you go to replace one, before you get to the point
of breakage, try heating the manifold around the sensor with a torch,
pref. oxyacetylene if you have access to one.

good luck,

nate

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