Helpful hints I've developed over the years:
- Don't use a crowfoot wrench - use a HEGO socket. It grips better, and is less likely to flex.
- Since the socket still does flex (just not as much,) you can bind it with a band-type hose clamp at the open end. That reduces it still further (the clamp may be applied before you put the socket in.)
- I've always had excellent results when removing these things while the area is as warm as I can tolerate - burning your hand can be considered an "occupational hazzard."
- "Feed it wax" is an old mechanic's trick for loosening stubborn fasteners. You use a torch with a pencil flame to heat the part with the male thread only! This forces the female threads to expand as the male-threaded part expands. At intervals, you remove the head and touch a candle or a block of paraffin wax (you can find this with canning supplies, and at some craft stores) to the junction between the two threads, or the junction between parts. The wax melts and wicks in between the threads. Only do this if you are replacing the part - or fastener - with the male threads! You get it hot enough to wreck the heat-treatment! If you do this on a bolt or screw, your SAE8 screw won't be SAE8 anymore! (This is why you only heat the male-threaded part, you're probably replacing it anyhow. The heat transferred is usually not enough to wreck the heat-treat on the female-threaded part.) I have detailed how to do with with frozen oil galley plugs before, it's the same principle.
- Under no circumstances are you to install the new HEGO sensor with dry threads, and you are to use a torque wrench! Coat the threads (but not the sensor tip) with a quality never-seez compound, and torque to 19-21 pound-feet on install. Failure to do either or both of these (dry threads, "gudentyt" torque) usually means you're going to have to remove the exhaust manifold next time and have the damned thing broken out on the bench...
Once you've done it, you see just how easy it is. The only reason(s) it takes me more than fifteen minutes to replace a HEGO sensor?
- I will at least visually check wiring before getting the sensor out. I've had wiring faults translate as HEGO fault DTCs.
- The damned thing is hidden behind far too much crap (engine fairings, accessories, ...)
- I'm just having a bad day.