Major catastrophe. ..sheared off oil sensor on B20

[Billy Smalls]

Really in trouble now...access is tricky to tap it out ..Would a spot of weld seals it sufficiently? Ahhhhh nightmareally any suggestions folks?

[Clan]

Originally Posted by Billy Smalls

Really in trouble now...access is tricky to tap it out ..Would a spot of weld seals it sufficiently? Ahhhhh nightmareally any suggestions folks?

I would take the manifolds off , it should be easy to drill it out a bit then use a thread extractor .

[Volvorama]

If you're contemplating welding, try MIGing a nut to what's left of the sensor. You might be able to use this to screw it out. Perhaps a nut sawn or ground down to half thickness to make it easier to weld through the hole in the middle.
There are of course various extractors available. Don't bother with the typical ones that look like an ice cream cone, they often break off in the hole. The snapon man and good engineering suppliers have better versions of these with less of a taper and also some that you hammer in. Of course an oil pressure sender already has a small hole in it which could help.
If possible I'd go for the welding option, as the extreme localised heat often loosens everything up.
The sophisticated and engineering option is to drill it out and re-tap the hole, presumably with the engine removed and stripped down, but even that could be risky.
Good luck.

[Derek UK]

To reinforce Mark's comment re drilling out, doing that will almost certainly introduce flakes of drilled metal into the pressurised oil ways. This is the last place you want it if you value your bearings.

[Clan]

Originally Posted by Derek UK

To reinforce Mark's comment re drilling out, doing that will almost certainly introduce flakes of drilled metal into the pressurised oil ways. This is the last place you want it if you value your bearings.

no problem , just crank the engine a bit to flush out the hole with pressurised oil .

[123GT-AMAZON]

Ok a master class needed in this situation ok here goes ,

If it's the ALLOY oil pressure sensor then burn it out with a blow torch which 9/10 times is the material used for those with a tapered thread but naturally the metal type would come out with weld if it is but I would be very surprised if it is metal .

Alloy will melt and drip out of the hole cleaning the thread on its path then it's free to refit new , drain oil and exchange for new and oil filter at the same time job done .

Happy melting .

Kind regards

Robert.w

[Clan]

Originally Posted by 123GT-AMAZON

Ok a master class needed in this situation ok here goes ,

If it's the ALLOY oil pressure sensor then burn it out with a blow torch which 9/10 times is the material used for those with a tapered thread but naturally the metal type would come out with weld if it is but I would be very surprised if it is metal .

Alloy will melt and drip out of the hole cleaning the thread on its path then it's free to refit new , drain oil and exchange for new and oil filter at the same time job done .

Happy melting .

Kind regards

Robert.w

I've never seen an alloy Oil light switch in any Volvo They are always steel from the factory , and have been dealing with them since late 1960's ..

If you had a non volvo alloy one heated it up with a fierce flame it would get blown INSIDE the oil gallery , not a good idea !

[Volvorama]

Only ever seen steel oil pressure sensors. Of course there are brass fittings for oil pressure gauges on some 1800s and as after-market parts on Amazons.

[CLIVERALLY]

It depends if you want your oil pressure guage/switch to work afterwards--- if not then the cheapest way ( I know I am going to get and avalanche of indignant comments) is to level it and JB weld it--it will out live your car and you could always find another route re the pressure switch..just a thought.

[Billy Smalls]

Hi All - well it's in the garage this morning and I will update on progress. I wrote the initial thread in a panic whilst in the pub using their wifi (and drowning my sorrows!)

I was just finishing off a job and noticed a wire that I couldn't identify, worked my way to the oil sensor and found it very loose - ah ha I thought, that's where my oil leak is. So I tightened it up - and pop! off it sheared!

Now, looking at the sensor where it sheared - I'd say it is alloy? It has that 'grainy' texture if you know what I mean, not a 'shiny' surface....

either way, the mechanics think they will be able to tap it out - access is a pig to do that due to the exhaust but if it comes to it - I'm not fussed about have the sensor on there (I've lived with it not working for 6 years) so they may weld a little plate over it???

will report back