C2 Temp Sensor Removal From an Aluminum Manifold

[James W.]

I need to replace the aftemarket temp sensor from my aluminum "461" manifold on my '65 Corvette. The proper socket size is an 8-point 15/16" deep well. This temp sensor was installed probably 6 to 8 years ago. I have a correct, used AC Delco temp sensor that I want to replace it with.

My questions are;

1. Are there any penetrating oils that should be used to try to help free it up?
2. Since the manifold is aluminum and the sensor brass, is heat a no-no to try to get it loose?
3. Should I use a 1/2" drive breaker bar to get it out or is this overkill?
4. If I get it out, when putting the other one back in, should it be installed without any thread sealant, yes or no?

Any tips from others who have had success in removing a temp sensor from an aluminum manifold that could pass them along to me? I don't want to ruin anything.

Thanks in advance.

James West

[John D.]

Re: C2 Temp Sensor Removal From an Aluminum Manifo

James, I use PB Blaster penetrating oil. I turn the intake upside down and let the PB soak in. Also I put it on the top side.
2. I sometimes use some Mapp gas and just heat the aluminum but I don't overdo it. I use the heat after the penetrating oil has had sufficient time to soak in.
3. 1/2" drive with proper socket
4. 100's of post here say just put it in dry.
5. Most of the time the tsu's come out in one piece and are reusuable but sometimes they come out in pieces or we have to cut them out. John

[Phil P.]

take your time and use lots of caution good luck *NM*

[Norris W.]

Re: C2 Temp Sensor Removal From an Aluminum Manifo

I always use heat. (map gas as John said) I've got several alum. intakes with threads pulled in either the temp sensor, and/or hose fitting holes, and I only assume that some previous owner tried to force a slightly corroded one out and galled it. I actually did one that was reluctant (a heater hose fitting) on the front of the intake on my 427 Biscayne recently without pulling the intake, but rather heating it outside and inside under the thermostat recently, and it came out really easy, where I hadn't been able to break it loose with a pry bar without pulling harder than I was comfortable with. (coolant drained of course)

I hadn't thought of the blaster idea, just figuring the way that alum. oxidizes and corrodes it may not make a path. I'll havta' give that a whirl next time.

[Verle R.]

Re: C2 Temp Sensor Removal From an Aluminum Manifo

Have you heard about using candle wax to remove things like that.

I watched a man use a torch to heat up a block, melt candle wax on the pipe plug that resisted a breakover with a cheater. After he melted the wax on the hot pipe plug it came out easily.

Verle

[James W.]

Re: C2 Temp Sensor Removal From an Aluminum Manifo

John,

I guess I should have clarrifed things a little more, the intake is on the car. I have a penetrating oil we use here in the shop called Kroil, we use it on a lot of power plant equipment such as steam turbines, gas turbines etc, that have not been apart for years and have had great luck with it, but also use heat along with it.

Explain the "mapp gas" use, what is it and how do you use it?

Thanks to all who have responded.

James West

[John D.]

Re: C2 Temp Sensor Removal From an Aluminum Manifo

James, I would forget about using the mapp gas when the base plate or intake is on the car for sure. Mapp gas: Methylacetylene Propadiene Stabilized.
Burns hotter than propane. For welding, brazing, and soldering. Dangerous stuff too.
I buy it at plumbing stores and use it for getting out fittings in intakes. Also use it for big soldering jobs as it gets the job done quickly. My plumber friend uses it all a lot and he recommended it to me years ago. Propane is a lot cooler. Typically Mapp Gas comes in a yellow 16oz tall container and the thread on top is typical of propane, etc. Brand name is Bramec No. 1202. John D.

[John D.]

Re: C2 Temp Sensor Removal From an Aluminum Manifo

Verle, I haven't heard the candle wax trick in an eon. When I was a kid living at home an old guy across the street used it for the same purpose and I forgot all about that until you mentioned it. We will try it just for fun on the next intake-fitting job. Those 63-65 FI water pump bypass fittings with the screw driver slot are horrible to remove. I farm that job out a lot and typically I am charged 35.00 and I feel I got a good deal. Thanks, John

[Verle R.]

Re: C2 Temp Sensor Removal From an Aluminum Manifo

John,

I had heard about it for a long time but never actually saw it until a few years ago. It worked like a charm. That was a cast iron engine block but it should work on aluminum with "gentle" heat.

Verle

[Timothy B.]

Re: C2 Temp Sensor Removal From an Aluminum Manifo

I used the candle wax to remove a thermostat housing bolt broke off in the intake manifold of my 67 300 HP car. Just to let everyone know it worked perfect and walked out like it was never froze but I did have a little stub to grab to turn out. I have one broke on a 1970 LT1 manifold I need to extract and I have not decided how to tackle this one yet (broke below top of manifold) I want to be very careful on this manifold.