The 02 sender is the perfect example of the 200 taps application,
featuring challenges from covalent, and ionic bonding, as well as
thermal expansion/contraction stress. Penetrating oils will help, but
tapping will cure the stuck 02 sender.

Remember, the tapping is NOT in the direction of rotation, but
perpendicular (from the 'head' of the bolt or nut) to jar/rattle the
threads at 90 angle to their thread face.

(and actually, it was my grandfather, Cyril L. Bulley, a career
automotive machinist for Chrysler and inventor who told me this little
secret.

Bringing ideas to life,
G. Matthew Bulley
Bulley-Hewlett
www.bulley-hewlett.com
AIM = IExplain4u
+1.919.658.1278
"Fax mentis incendium gloria culpum"

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@GERRY.VANAGON.COM] On Behalf
Of John Rodgers
Sent: Thursday, November 07, 2002 9:35 AM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: 1984 Frozen stuck O2 sender

I believe it was G.M. Bulley who postulated the "200 Taps" method of
loosening stuck/frozen bolts, fixtures, etc. It works. But of course the
application of penetrating oils and corrosion removers  preceeding the
200 taps also applies. Patience is the key. Sometimes the application of
ice/cold or heat or the combination of the two helps a lot.

John Rodgers
88 GL Driver

Karl Wolz wrote:
> Spray that sucker with some lightweight oil, such as (at least -
WD-40;
> better - Liquid Wrench; best - Kroil or some such thing)  Let it set
for a
> while, then spray again.
>
> Take yourself a Stilson wrench (pipe wrench) and put a bit of pressure
on
> the sensor.  Start tapping the wrench with a smallish hammer.
>
> Do the "Anvil Chorus" a few times, while spraying (soaking) again a
couple
> times.  This should break loose all of the rust, sludge, and other
crap
> that's binding the threads.
>
> If still not free, fit a 2" diameter by 6' long steel pipe (like for
chain
> link fences) over the end of the wrench, and gently (you have a lot of
> mechanical advantage now) increase the pressure on the wrench.
>
> If still no luck, you'll probably need to buy a new pipe - but there's
> always the "blue wrench"!
>
> Karl Wolz
>
>
>
>>Any suggestions on the removal and replacement of a frozen 02 sender.
I
>
> really do not want to replace the exhaust pipe.
>