Primary O2 Sensor Issue

[r0cknry]

Hey all, big dilemma I have here!

My primary o2 sensor went bad. Had all the common symptoms like rough idle, hesitation and a lot of jerkiness when driving. I ordered a new one and tried to remove the old one myself but of course its seized on and wouldn't budge at all. Heated it up with torch, PB blaster etc and wouldn't budge.

Took it to the local Mazda dealer. They quoted me $240 dollars to only remove the old one and I would need to go home and install the new one myself.

They called back today and of course they couldn't get it out, and even worse they stripped the threads. Now they want 1300 dollars to install a whole new down pipe. I of course can't afford that, not to mention its ridiculous!

So, what does everyone suggest I do? Since I unplugged the old one, the car is driving fine now but I know my gas mileage is going to suffer. Does anyone have an accurate idea of how much my gas mileage may decrease because of this?

An idea I had was to acquire a stock downpipes myself and try to swap it out with my new o2 sensor but Ive read its a pretty big job and not sure if its something I can tackle on my own with only basic tools and jack stands.

Ant ideas? Thanks!

Car: 2006 Mazdaspeed 6
Mods: None
Miles: 110,000

[HawkeyeGeoff]

Originally Posted by r0cknry Hey all, big dilemma I have here! My primary o2 sensor went bad. Had all the common symptoms like rough idle, hesitation and a lot of jerkiness when driving. I ordered a new one and tried to remove the old one myself but of course its seized on and wouldn't budge at all. Heated it up with torch, PB blaster etc and wouldn't budge. Took it to the local Mazda dealer. They quoted me $240 dollars to only remove the old one and I would need to go home and install the new one myself. They called back today and of course they couldn't get it out, and even worse they stripped the threads. Now they want 1300 dollars to install a whole new down pipe. I of course can't afford that, not to mention its ridiculous! So, what does everyone suggest I do? Since I unplugged the old one, the car is driving fine now but I know my gas mileage is going to suffer. Does anyone have an accurate idea of how much my gas mileage may decrease because of this? An idea I had was to acquire a stock downpipes myself and try to swap it out with my new o2 sensor but Ive read its a pretty big job and not sure if its something I can tackle on my own with only basic tools and jack stands. Ant ideas? Thanks! Car: 2006 Mazdaspeed 6 Mods: None Miles: 110,000

If you don't have any internals or AP I'd suggest just sticking with an OEM downpipe. If you donate you can find one on here VERY easily (or just ask some locals that are modded).

I think you can do this job with the help of some locals....MS6 are a little bit bigger PITA to do and you will probably have to replace some bolts that you will smoke trying to take it out; that being said, be prepared for that.

Also, since you are running without a primary O2 sensor, it's running off a simulated map. I would not WOT (or boost really) on these conditions just because you aren't getting any feedback to the ECU so it really doesn't know exactly what's going on....it's pretty much just guessing. This is the map the vehicle runs in the rapid heat up stage (cold start) until the O2 sensor heats up enough. What I'm getting at: your fuel mileage will SUCK.

Another option would be to tap the downpipe if you can find the right size tap. I'd recommend unhooking the downpipe from the turbo and placing a towel or something under the O2 sensor hole to catch any shards from the O2 sensor bung that get shaved off when you do this though.

GL!

[Killer95GT302]

When I got my O2 replaced under warranty, the dealer also stripped the O2 threads but they claimed they were able to helicoil it.

Is this the first time the O2 has ever been removed? There may be enough material to do the same thing.

For $1300 you can get a new turbo and cheap downpipe with DIY install - that's a lot of cash to fix an O2. If your mechanical ability isn't that great though, I recommend donating and seeking the help of forum members or friends.

[HawkeyeGeoff]

Originally Posted by Killer95GT302 When I got my O2 replaced under warranty, the dealer also stripped the O2 threads but they claimed they were able to helicoil it. Is this the first time the O2 has ever been removed? There may be enough material to do the same thing. For $1300 you can get a new turbo and cheap downpipe with DIY install - that's a lot of cash to fix an O2. If your mechanical ability isn't that great though, I recommend donating and seeking the help of forum members or friends.

This. I am decently local to you, so if you were to donate to the forums, I may be able to lend a hand.

[r0cknry]

Thanks for the quick replies everyone! I really appreciate it.

I am more than happy to donate to the forums. (was previously a vip member but I suppose it ran out).

If some local guys were willing to help out, other than a new downpipe, is their anything else I need to get? Maybe a new gasket and bolts?

Thanks, Ryan

[someguy]

Tell them to fix it! It's absurd to think that they'd force you to pay for a new downpipe if they stripped the threads. As said above, there are other ways to fix it other than replacing the piece, you can helicoil or weld in a new bung.

[r0cknry]

Hey everyone, I guess I was given some poor information from the dealer before.

They were able to remove the old sensor, but the new sensor won't sit properly because the threads on the DP are stripped. I think this make the situation easier?

I have never heard of helicoil but I did a quick search and it seems pretty simple. Would that be my best bet to get the new o2 sensor to stay put?

Thanks!