Stuck O2 sensor
Thread Starter
Junior Member

Joined: May 2010
Posts: 64
Likes: 1
From: North Carolina
Year: 1996
Model: Cherokee
Engine: 4.0 L V6
So pretty sure I know where this thread is going to lead, but I'm open to suggestions.
Just trying to replace my upstream o2 sensor, however the fricken thing won't budge. I've tried a standard wrench, adjustable, and even vice grips which tore it apart only to not have it budge. Attempted to tighten it a bit and then try to loosen again thinking maybe it'd budge but that didn't work. I've PB blasted the hell outta it. Even tried cutting the wires and getting the other end of my closed wrench on it which didn't last long given the vice grip damage. Only thing left I can think of will be to clean the hell outta everything and apply a torch for a min or two and try the vice grips again. However a bit hesitant as I've a transmission leak going on so everything is coated in fluid.
Again, open to suggestions...
Just trying to replace my upstream o2 sensor, however the fricken thing won't budge. I've tried a standard wrench, adjustable, and even vice grips which tore it apart only to not have it budge. Attempted to tighten it a bit and then try to loosen again thinking maybe it'd budge but that didn't work. I've PB blasted the hell outta it. Even tried cutting the wires and getting the other end of my closed wrench on it which didn't last long given the vice grip damage. Only thing left I can think of will be to clean the hell outta everything and apply a torch for a min or two and try the vice grips again. However a bit hesitant as I've a transmission leak going on so everything is coated in fluid.
Again, open to suggestions...
Senior Member
Joined: Sep 2014
Posts: 625
Likes: 3
From: Austintown, OH
Year: 2000
Model: Cherokee
Engine: 4.0
tranny fluid is all the way up towards the upstream sensor?
Heat would probably be the best bet, I would just be careful and keep it contained in that area. Maybe even running it for a while so the manifold heats up to operating temp and then applying heat will cut down on the time you'd have to have a torch in there..
Just and idea..
Heat would probably be the best bet, I would just be careful and keep it contained in that area. Maybe even running it for a while so the manifold heats up to operating temp and then applying heat will cut down on the time you'd have to have a torch in there..
Just and idea..
CF Veteran
Joined: Mar 2012
Posts: 1,024
Likes: 2
From: Quebec
Year: 1996
Model: Cherokee
Engine: 4.0L
yep i'd get it up to temperature and by being careful not to burn yourself on the exhaust / muffler / cat, i'd try this way. then if that doesn't do it clean everything and use a torch
Senior Member
Joined: Nov 2013
Posts: 616
Likes: 4
From: Vernon NJ
Year: 1998
Model: Cherokee
Engine: 4.0
When I changed mine I had to break everything off of the old sensor and get a standard socket with a breaker bar and cheater pipe. It was in there good. I did not have access to a torch or MAP gas.
Trending Topics
CF Veteran


Joined: Mar 2015
Posts: 1,203
Likes: 154
From: Northern CT
Year: 1995
Model: Cherokee
Engine: Turbo 4.0
X2 mapp torch and a big pipe wrench. Don't be afraid to use a cheater bar. I have had great success with Harbor Frieght wrenches. Haven't been able to snap one yet even with 4 feet or cheater bar. If you have access to oxy acetylene I would implore you to use that first. It will get the fitting hotter which means less work for you.
CF Veteran
Joined: Aug 2011
Posts: 10,489
Likes: 24
From: Nor-Cal Coast
Year: 90,84
Model: Cherokee
Engine: 4.0,2.5
Gosh, thanks Pete,
Agreeing with heat and the pipe wrench. If there is any way to strike it with a hammer while applying max torque...the shock -wave sometimes helps. Hitting-taping, the pipe wrench on the back can also help it bite in better, an art there....
I spent $16 on a can of this Kroil. After only a couple of experiments I'll recommend it. Yes, spendy, but really just a little dab, (drop) is all it takes. I expect my can to last meany years>>> http://www.kanolabs.com/
Agreeing with heat and the pipe wrench. If there is any way to strike it with a hammer while applying max torque...the shock -wave sometimes helps. Hitting-taping, the pipe wrench on the back can also help it bite in better, an art there....I spent $16 on a can of this Kroil. After only a couple of experiments I'll recommend it. Yes, spendy, but really just a little dab, (drop) is all it takes. I expect my can to last meany years>>> http://www.kanolabs.com/
Last edited by DFlintstone; Mar 10, 2017 at 05:17 PM.
CF Veteran
Joined: Aug 2010
Posts: 8,357
Likes: 103
From: Canton, MI
Year: 1999
Model: Cherokee
Engine: 4.0
CF Veteran
Joined: Dec 2015
Posts: 2,139
Likes: 93
From: Syracuse, NY
Year: 1996
Model: Cherokee (XJ)
Engine: 4.0L
I spent $16 on a can of this Kroil. After only a couple of experiments I'll recommend it. Yes, spendy, but really just a little dab, (drop) is all it takes. I expect my can to last meany years>>> http://www.kanolabs.com/
I got introduced to it a few years ago, working on a Honda, and have not been without it since.
::CF Moderator::
Joined: Aug 2011
Posts: 43,971
Likes: 1,578
From: Prescott, Az
Year: 1990
Model: Cherokee (XJ)
Engine: 4.0
::CF Moderator::
Joined: Aug 2011
Posts: 43,971
Likes: 1,578
From: Prescott, Az
Year: 1990
Model: Cherokee (XJ)
Engine: 4.0
Gosh, thanks Pete,
Agreeing with heat and the pipe wrench. If there is any way to strike it with a hammer while applying max torque...the shock -wave sometimes helps. Hitting-taping, the pipe wrench on the back can also help it bite in better, an art there....
I spent $16 on a can of this Kroil. After only a couple of experiments I'll recommend it. Yes, spendy, but really just a little dab, (drop) is all it takes. I expect my can to last meany years>>> http://www.kanolabs.com/
Agreeing with heat and the pipe wrench. If there is any way to strike it with a hammer while applying max torque...the shock -wave sometimes helps. Hitting-taping, the pipe wrench on the back can also help it bite in better, an art there....I spent $16 on a can of this Kroil. After only a couple of experiments I'll recommend it. Yes, spendy, but really just a little dab, (drop) is all it takes. I expect my can to last meany years>>> http://www.kanolabs.com/
If Don spent $16 on penetrating oil, it must be great!!!!!
Actually, it's worth every penny, even to a guy who squeezes a nickel til the buffalo ****s.
Thread Starter
Junior Member

Joined: May 2010
Posts: 64
Likes: 1
From: North Carolina
Year: 1996
Model: Cherokee
Engine: 4.0 L V6
Well, crappy update. Heated the hell outta the sensor, attached a socket and breaker bar and applied my entire body into it. Now the socket spins around it with force (the ends have been rounded out on the sensor) and the sensor hasn't budged an inch. To top it off, the socket is now stuck on it and haven't been able to bash it off with a hammer. Any new suggestions? I'd prefer not to have to remove and replace this portion of muffler as it was just replaced about two years ago with all Borla parts.




