'89 Audi 200TQ Stripped O2 sensor boss
John Larson
j.d.larson at verizon.net
Thu Jun 30 14:05:53 EDT 2005
The discussion has gone thusly: "well the O2 sensor came out along with
the threads in the exhaust manifold. What can be done in this case, do I
need a new exhaust manifold? can it be retapped?
Can't retap what isn't there, though I suppose you might be able to
helicoil it (no idea if expansion+contraction from the significant
heat cycles would affect it). Finding an exhaust shop and having
them weld up a new bung would probably be cheaper, easier, and more
reliable in the long run."
It's 18mm, same as some older Ford spark plugs. Inserts, as well as
helicoils, are available, though you might have to find one of the better
(and older) automotive machine shops to do it. Since this isn't an uncommon
problem, I'm sure you can find someone to fix it. I do things like that
in-house, and on the car, and there must be other shops that do that as
well. Worst case, you buy the appropriate kit and do it yourself. If
that's the case, I'd look for an insert kit. Gonna be far cheaper than a
helicoil setup. Welding a steel repair bung to a cast iron manifold is out
of the question, IMO. John
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