ok the o2 sensor seems to be stuck WILL NOT COME OUT stripped the bolt around it what should i do ???

We run into these every so often. Had two last week. aarrrgghhh. It is a 7/8" hex. Buy an O2 socket. They are six point, instead of 12 point. You'll have less of a chance of rounding the head...You do not want to do that. Only, if you feel comfortable doing it, and have a fire extinguisher and/or garden hose ready,Apply heat, very carefully so as not to catch anything on fire, then quickly get the socket and ratchet in there and hopefully, you can get it to come out. If the threads are damaged in the exhaust, which they probably will be, buy a 14mm tap and retap the threads, again being very careful to get the tap started straight. Be sure to use anti-sieze on the threads of the new O2 sensor so the next guy will be able to remove it.
Loren
SW Washington

ok one question would you be able to drive without an o2 sensor in the exhaust what would happen in the long run...

Nope, can't run without one. The O2 sensor directly controls fuel delivery. Severe engine damage is possible, Catalytic convertor damage likely. Sorry.
Loren
SW Washington

(This post was edited by Loren Champlain Sr on Apr 6, 2009, 7:03 PM)

ok how bout this drilling a new hole into the pipe and disconnecting the old one and cutting it off so it doesnt look noticeable would that be ok

These are a pest as Loren noted. At some point replacing the pipe (pretty big bucks) could be the best option.

If you could remove the whole pipe which should look something like this....



You might be able to weld in a new threaded nut or if there's room (doesn't look like it) make a new threaded hole to receive the sensor and properly plug off where original was with perhaps an oversize self tapping drain plug if you can find the right size.

They look something like this....



T
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Tom Greenleaf - MetroWest, Boston
http://acsource.net/acforum/index.php

Tom brought up a very good point. A light bulb lit up in my head. (okay, it's a dim bulb) You could take the assembly off and take it to a muffler shop. They surely could extract the old sensor for you. As far as the threads, if they are damage beyond repair, the muffler shop could probably braze the new sensor in for you. But, next time, the assembly will have to be replaced. As far as drilling a new hole and installing the sensor there, won't work. The pipe is too thin. As Tom mentioned, there is a threaded nut welded on the inside of the pipe for the sensor to screw into.
Loren
SW Washington