02 sensor stud broken advices

Need to replace my 02 sensor to get mine to pass inspection. One side was a stud and one side was a bolt so apparently one side broke off on the p.o and he fixed it using a very low quality bolt. Which broke off flush.. what are my options here? Can’t remove the exhaust pipe due to the cat being welded in. Also some of the p.o’s craftsmanship. Any ideas? Can an exhaust shop cut that section out and weld me in a new flange with new studs and everything? I attached a very bad pic sorry best I could do

 

Yeah to what you're saying about the exhaust shop fix it. It's called a bung(I know I know)

 

Old and new. I do have the correct new sensor don’t I?

 

Need to go off of the actual part number, there were a few sensors used between the various configurations and models

 

According to rock auto and the research I’ve done I have the correct sensor. From what I’m seeing I can’t even get a sensor like the old one for my truck. They all bolt in using the studs. The old one seemed to screw in and was held down by the studs. Doesn’t make sense

 

Yeah you're new one is definitely the right style and very well is the one as long as that's the right part number. How the hell was that old one even secured to the bung? It has to be like your new one. Sensor is mounted to a flange and the flange secured to the bung. There should be two studs coming out of each end of the bung that flanged sensor slides over and then two nuts are used to secure the sensor down on those studs.
Shoot, there's gotta be a pic that would make that 10 minutes of typing much easier to visualize lmao my bad I'll look for a pic

 

the old one is an aftermarket Bosch sensor. New one is the corect OEM part.

Some aftermarket o2 sensors have a screw-on flange but strange that it's missing, though. Sensor was probably replaced in the past but since a stud broke, they put it without the flange but I wonder how it was holding there... maybe they did thread the hole, or forcefully shoved it in there?

As to repair the bung, you could ask around if muffler shops could weld in a new one, or else you will need a new exhaust pipe (available on rockauto). It's bolted to the cat with a flange so it shouldn't be too hard to replace

Or a possible repair would be to put some stainless hose clamps going around the exhaust pipe and over the sensors's flange, holding it in place. Like this:

 

One can buy a bung with the threads to match the sensor.

You screw it in plug it in or hard wire to the harness what ever style you have

simple to replace the bung on the truck can be a pain

I am to the point I don`t mess with broken studs off comes the old bung on goes a new one.

I feel for those unable to weld

 

Ngk sensors come like your old sensor. The screw in bung bolts down to the two studs, and the sensor screws out and is replaceable without the bung plate. If you still have the bung plate from your old sensor, the easiest way I see to fix it is to weld your old bung plate over the broken stud, and replace the o2 sensor with a ngk screw in type. It is available with or without the bung plate. The ngk kit with the bung is about twice the price as the factory denso replacement sensor, but in your case, it would be worth the extra cost. Not sure if these two examples are your correct part, but here’s the difference in what NAPA offers.

 

Yeah I would replace that section of exhaust if the flanges on the cat weren’t welded to the pipe between the manifold and cat. Just trying to pass inspection not looking to spend a whole lot. Talked to a local shop taking it at 12:00 for him to look at it and see if he can get the rest of the broken stud out and replace the stud. Worst case he also said Boshe offers a screw in style 02 and he could cut this section out and weld in a new one with a screw in style bung for 50$ or so. So we will see

 

Weld this over your existing one.

 

Thought about that to. Gonna see what the exhaust shop says today. Might be my final option

 

Do not let anyone persuade you to use any o2 sensor or A/F sensor other than Denso or OEM Toyota(made by Denso). Toyota ECMs can have issues with non Denso O2 sensors.

 

Ended up ordering this. When it comes gonna weld it over what was there

 

Were you able to weld a new one over top of the old one no problems?

 

Looks like OP hasn’t been back on the forum since October 2021.

 

If you still have a stud/partial stud showing, can try this to remove it using a stud extractor. Most auto/HW stores should carry something along the lines of this (what I used):

ARES 70016 - Damaged Bolt and Stud Extractor Tool - Grips and Removes 1/4" to 1/2" Studs - Ideal for Broken, Rounded Off, Painted Over, and Rusted Tight Bolts

https://www.amazon.com/gp/product/B01GKEBG9I/

If you can remove it, just thread in a new stud.