I was trying to remove a crank position sensor on a 4.7l. I followed a guide, I think I even found it on this site somewhere. I spent over an hour wiggling it back and forth, and tugging on it, no progress at all. I have smaller tires so I reached in the wheel well, put some vise grips on it, and pulled hard while someone lightly wiggled it, did this for maybe 15 minutes, and then it just shattered into 20 little pieces, little brass connectors and all. Now the end of the sensor that has the little rubber O-ring is still stuck inside the block!. It's pretty much broken off flat, I can't get needle nose, pliers, or anything to grab ahold. Can I drill it out?

 

Can you take a picture of what you have? Or shall I say don't have..haha

talking about the piece stuck in the block.

 

This is whats left of it. I sort of mutilated it, there are 2 holes from self tapping screws and then there is a drywall screw broken off in there. I thought I'd give that a try but no luck...

 

I'd pool up some Penetrating oil and let it sit overnight. Then I would drill 2 holes on opposite sides and do your sheetrock screw thing again, but go get yourself conrete screws(blue) this way they won't break off.
I wouldn't drill too close to the outer edge. 2 screws will give you the ability to twist and turn it.

* also, have you tried scouring the outer edge with a sharp pick? It doesn't look like it was even moving in there? rusted tight? tap the lip lightly with a flat edge hammer.

 

I would drill thru it and change the oil after installing the new one, but that's just me.

 

Well, It took a good 8 hours, but finally, it's (mostly) out. I used 3 different sized screws, finally on the 3rd I pulled the magnet out, but the plastic stayed in. It was loose, but there was a lip of rust that I couldn't pull it over, I tried to chisel and chip it apart to get it out but eventually gave up and just pushed it in. I sanded and filed for a good hour until the new sensor finally, very snugly, fit in. ... Sadly, the sensor was not my problem.....

 

wow, that's insane. At first I was like wtf is that wire doing in there and then holy crap he used a cumalong...lmao.

I figured it had to be rust stopping you and those concrete screws are tougher than sh*t.
Glad to see you atleast got the letal bulk part of it out. That piece will likely just sit at the bottom of the pan for it's life. I doubt you would have any problems unless it makes it's way to the drain hole and super slows the oil from coming out, then you'll need to push it in with a screw driver to let the oil out..haha unless of course you can get needle nose pliers in there to pull it out?

 

That is an insane amount of trouble and work. glad you got it out

 

Same EXACT same problem, same as pictures and everything. Even BROKE the come along I used. Finally got it to your last picture with a bunch of heat, installing the bolt and using it as the fulcrum to get my carpenter hammer's claws under the cement screw and finally working it out. Could NOT get that last part/photo out and pushed it into the block. Did you leave it there or remove the pan and get it out? What a total PITA.

 

As much as i like working on my own truck, it's nightmares like this that justify for me having the dealer do certain repairs. At least with a dealer, the nightmare falls on them and any damage they cause in the process they will be responsible for.