Broken Exhaust Sensor - Ford Powerstroke Diesel Forum
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post #1 of 10 Old 10-26-2010, 12:56 AM Thread Starter
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Broken Exhaust Sensor

My exhaust sensor is broken on my DPF. It broke trying to take it out of the DPF. So now I have part of the sensor still in the DPF's bung.

Any tips on how to get the broken part of the sensor out of the bung without damaging the threads?

Thanks...

Neil

2010 F250 Lariat CC/SB 6.4, 4x4, FX4
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post #2 of 10 Old 10-26-2010, 04:31 AM
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Use lots of penetrating oil, let it soak for a couple of days. Then grab the top of it with vice grips and smack the handle with the palm of your hand to "shock" the fitting. It should come out without too much trouble.

-John
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post #3 of 10 Old 10-26-2010, 09:44 AM Thread Starter
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Vice Grips

It broke off pretty clean and I have nothing to grab on to. I was thinking of trying to drill it out but I am worried about damaging the threads. Never-the-less, I will being soaking it with PB Blaster.

Thoughts?

2010 F250 Lariat CC/SB 6.4, 4x4, FX4
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post #4 of 10 Old 10-26-2010, 11:11 AM
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You could try a left handed drill bit, once you get deep enough it may grab and spin out.

-John
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post #5 of 10 Old 10-26-2010, 02:05 PM Thread Starter
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Left Handed Drill bit

I have never heard of a left handed drill bit. Are they avaialbe at Harbor Freight or Sears? Any idea what size I need?

Thanks...

2010 F250 Lariat CC/SB 6.4, 4x4, FX4
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post #6 of 10 Old 10-26-2010, 02:49 PM
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I think he is talking about an easy out for broken bolts, drill a small hole and start to screw it in and it should start to back itself out. This is taking into account that you have soaked it in penetrating oil for a few days...

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post #7 of 10 Old 10-26-2010, 03:40 PM
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Quote:
Originally Posted by blackcloud2k View Post
I think he is talking about an easy out for broken bolts, drill a small hole and start to screw it in and it should start to back itself out. This is taking into account that you have soaked it in penetrating oil for a few days...
They do make left handed/reverse drill bits but I think a ez out might work also. The sensor bolt should already have a hole right? Is there any part of the sensor stem blocking the hole? If not and you just have a clean break with nothing blocking the hole then you can get a ez out or reverse drill bit and try to extract it. Either way I would buy a kit with 3 or 4 different sizes.
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post #8 of 10 Old 10-26-2010, 03:53 PM
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I would try an ez out or extractor. I bought this set awhile back for my JD lawn mower, it worked great.
Shop Kobalt 10-Piece Screw Extractor Drill Set at Lowes.com


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post #9 of 10 Old 08-16-2013, 12:09 PM
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Older thread I know, but other people are still having this problem so I thought I'd post a solution. Replacement threaded exhaust sensor bungs for these are now available on Ebay. You can remove the old bung and weld a new one in it's place, or just drill a hole and weld the new one next to the messed up one.

Here is the Ebay link:

OE Style Exhaust Gas Temp EGT Sensor Bung for Ford Powerstroke Diesel 6 4 6 7L | eBay

I hope that helps someone^^^
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post #10 of 10 Old 08-16-2013, 04:42 PM
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I haven't broken mine off yet and its the only one left to transfer over to the straight pipe. Have been dousing it with PB Blaster for the last 4 days and still no joy. Even using a 6 point craftsman wrench and its still wanting to strip the bolt head. Yes, I know I dont need them in the straight pipe but it keeps the electrical terminal from getting moisture in it. Any new advice getting the REALLY stuck ones out. It spent the last 85000 miles in the DPF.

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