02 Sensor Replace

Was under my truck this week and seen the 02 Sensors one before and after the cat, the rust on the exhaust pipes was terrible, if they need to be replaced with all that rust is it even possible to remove them with out damageing the exhaust pipe? Special tools needed also?

 

I replaced both O2 sensors in the 1st Gen Tacoma and it was a complete nightmare. You probably have the flange type sensor where the threaded studs are welded to the exhaust and you secure with two castle nuts. The corrosion after only 3 years rounded the hex shape of the nuts so I had to carefully dremel the nuts off. I believe I couldn't get a speciality socket that grips a stripped nut because the O2 sensor body was in the way. I also used a low profile metric die to remove what was left of the corroded nut being careful not to damage the stud. It took me probably 3 hours to remove the O2 sensor and then I used stainless nuts and lock washers afterwards. The next time I changed the O2, it took 10 minutes instead of 3 hours.

 

I just replaced one on a 2004 without any issues. Get a can of PB Blaster Penetrating Catalyst. Apply this stuff to the treads a few times before doing the sensor removal work.

 

there is a tool, o2 sensor socket, i think you can get it from autozone (got mine of the snap on truck ) definitely want to spray with penetrating lube. i use toyota penetrating lube. it should just come off, however i have had some come in with soooo much rust on them i had to replace the exhaust mid pipe.

 

i have removed mine a few times with no problem BUT the lasttime i tried to remove it, the nuts were stuck on there so much that BOTH the bolls sheared off at the edge of the pipe and caused bigger problems...use penetrating lube and dont just start torquing on them...