'89 Audi 200TQ Stripped O2 sensor boss

[Jim Dupree]

I have had several over the years that looked really
bad but I was able to run a tap thru what was left of
the threads and they cleaned up OK. Not great but OK.
I was skeptical that they would hold but the new O2
tightened down OK and stayed put. I have also had to
installed an insert into my old 4k (4cyl) manifold as
there was not enough left of the original threads.

Good Luck
Jim


--- John Larson <j.d.larson at verizon.net> wrote:

> 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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