severed temperature sensor - F78

Submitted by scotsgent on

Forum: 

I tried to replace a faulty temperature sensor on my Fourtrak F78. The old one came out no problem, but the new one had a tighter thread. I severed the new one through overtightening!!

It is a hollow brass tube, now flush with the side of the head casting and is still in the head and so far still holding a watertight seal.

However, I need to get this sorted since I have no method of keeping an eye on the temperature.

I intend to take the vehicle to my local garage, but I am concerned that they might bodge it and I finish up with worse problems such as a sensor which is impossible to ever remove or maybe debris in the cooling passages.

Any advice as to the best way of removing this broken sensor? - maybe a stud remover or are there any other methods I could discuss with the garage before I let them loose?

Any suggestions gratefully received.

Cheers, Terry

Drill the core out with

Submitted by assassin on

Drill the core out with progressively larger drill bits until the hole is just smaller than the hole so it does not damage the threads.

Now the side is so thin it can be gently tapped with a hammer and centre pop towards the middle and the now thin wall will collapse in on itself. You will need to break it in from both sides, and you will need to flush out your cooling system to remove any swarf.