Steps to replace an exhaust sensor mounting boss:

The following procedures are intended for people with a certain level of mechanical repair experience. If you lack the required safety equipment, or are uncomfortable performing this procedure, an automotive repair facility can do this for you. In fact, some of our best customers are actually dealerships and independent repair shops.

Another even more cost effective option if you are able to remove the damaged component from the vehicle, is to bring the component to a welding shop to have the repair performed. Then simply reinstall the repaired component with any necessary exhaust gaskets.

As you can see, drilling out the remains of the old sensor is not a very viable option. The shrouded seat inside the bottom of the mounting boss which seals against the sensor can easily be damaged by a drill bit. Not that anyone could keep a drill centered very well anyway with the center portion of the sensor still there. Certainly you could replace the entire component with a new one for a couple thousand dollars or more, but who wants to spend that kind of money? It is best to simply replace the threaded sensor mounting boss, install a new sensor, and be done with it.

Why use our product to repair your exhaust system component?

Because it will save you thousands of dollars over replacement!

​Our customers have saved several million dollars in repair costs!

This is what it looks like upon removal of the damaged EGT mounting boss.

Note: if drilling a new hole, do so in a slightly different clock position on the same plane as the original so as to avoid drilling in to catalyst or DPF substrate material while ensuring sufficient wiring length and routing.

​To ensure a quality weld, all surface corrosion should be removed from the repair site. We prefer to use an air powered die grinder with an abrasive disc, but use whatever you have. The metal should be clean and shiny. Remember to wear eye protection.

​​PREMIUM CNC TURNED COMPONENTS

In order to remove any residual oils which could contaminate the weld, the repair site should be degreased prior to welding. We prefer a fast evaporating solvent like non-chlorinated brake cleaner. Then position the replacement  mounting boss over the hole where the damaged one previously existed. 

​Remove the damaged sensor mounting boss: 

Often times you can simply heat the old one with an oxy-acetylene torch until it glows bright orange. Then use a pipe wrench to twist it off cleanly. If you do not have access to a torch, or if that doesn't work, don't worry. Many people simply leave the damaged one in place and drill a hole to install the replacement right next to it. Another option is to use a grinding wheel to grind the old mounting boss completely off. 

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Remember to wear ALL necessary protective equipment.

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Obtain a new sensor and install it in to your new mounting boss. We recommend putting some nickel anti-seize compound on the threads to prevent from having this problem again in the future.

Pat yourself on the back for money saved, and a job well done!

Due to flammability concerns, always keep a fire extinguisher handy, and make sure ALL degreasing agent has completely evaporated. If performing the repair in chassis, make sure to disconnect the vehicle batteries and any sensitive modules: PCM, TCM, ECM, BCM, IC, etc. (Refer to manufacturer's repair manual recommendations).

Then weld the new mounting boss to the component while observing all safety practices. 309L Welding wire is preferred; however most of our customers use MIG welders with standard steel wire and have great success. Brazing has also shown to be an acceptable attachment method when performed correctly.