Russ Blazer

Ok... so about 2 years ago my twins turned 16... the deal I made with them was simple. I will match you dollar for dollar up to 2500 for your first car. They both bought XJs. My son bought a 1999 Sport for 3000 and my daughter bought a 1998 Classic for 2300 (which has never caused me one problem).

So since the purchase of the 1999 ... I've learned a lot about automotive corrective maintenance... and I'll be honest... I've had a lot of fun learning. We've changed motor mounts, brake systems, coolant systems, top end of the motor...etc etc

But here's the RUB... I live in MD... it almost communist, and in order to pass STATE emissions, I can't have codes. I have codes. Codes for the O2 sensors. Now it took me a week of watching YOUTUBE to get those buggers out. But they are out. Now getting them back in is a different story. Here is what I have done:

1, Tried thread chaser... upstream it worked... downstream it didn't
2, Bought a thread "maker".... used heat to spin it into the downstream bung. Went in crooked and O2 sensor just spins crooked in the misaligned hole I created.
3. Figured the downstream bung was ruined... so I just needed to seal it off in order to get the vehicle to a shop to weld on a new bung.
4. After successfully "chasing" the upstream threads, I went to install the sensor..... No joy...cant get the O2 sensor to thread.

I am at my wits end. Should I just take to a muffler shop to weld in new bungs?

jordan96xj

Yes, probably. Muffler/exhaust work like that is usually pretty reasonable (cost) and quick. They have the right toys to get it done efficiently. If it was my Jeep, that is exactly the type of job I would farm out to a shop (I do most everything myself). As long as they didn't try to give me a run around or up sell me on the job. This is mostly because while I carry quite a few tools at home, I really am not well equipped for exhaust/muffler work, so things that would be a few minutes for them, could take me hours.

DFlintstone

This sounds like one of those times it's better to just call it a night. Have a beer. It shouldn't be that hard, things might look different tomorrow. There is no harm in gently smoothing, tapering the first few threads on the sensor, & heck, the bung too if you can reach it.Likely there is just a burr or something, then the perfect angle can take a few tries. (try using your other hand if you can)

97grand4.0

If you are sure you have the right sensor with exactly the same thread and it wont go, get a tap and try it. Otherwise my next would be to order a new exhaust off ebay, which would likely be cheaper than a shop to replace the o2 bung and sensor. Most will tell you something like they won't install your part, only their part$.

PatHenry

If you do replace the pipe, be super careful about picking the right brand. I got a Walker pipe for my 95 and the bung was not in the same location - and the new one is reeeeeally tight.

An exhaust shop should be able to take care of it easily.

gat

Photographs, please.
If I could see the threads, then I might better understand the problem. I'm familiar with thread restorers/thread chasers. I've not heard of thread makers... I'm not sure what those do.

Russ Blazer

I meant an O2 Tap from lisle. Sorry to confuse.

Russ Blazer

Back up and running... thanks again for the feedback!