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So while installing a new oil pressure switch on my '02 4.7 1500, I overtightened it to the point where it was stripped to all hell and just spinning in place. Who knew it has a tapered pipe thread? I tried removing it but it wouldn't come out, just kept spinning. The area was super tight and I had to move the drive belt and sway bar out of the way to have enough room to get my right angle drill in there. I used an extractor set and finally got it out today. I feared that I had cracked the block but to my surprise looks like I got the best case scenario here. Please see pics. Has this ever happened to anyone? What should be my next steps to get a new oil pressure switch installed. I've amassed an arsenal of options but I don't want to screw it up. Stainless steel pipe thread sealing tape, drill & tap, JB Weld, pay a professional to come do it? Any advice would be appreciated. I'm tackling it this weekend.
Get a NPT (national pipe tap) the same size as the pressure switch. You should be able to tap down more. You may need to get a fitting between the switch and the block. You can use a pipe die to get a little more depth of the fitting since it looks like you don't have room on the switch. Use the thread sealant on both when you install them.
Ouch. Sorry you're going thru this, bro. I just replaced mine on the Dakota less than a month ago and thought to myself how easy it would be to break that thing off. I wouldn't use that JB weld stuff because it may not stand up to the oil and leak in the future. See other option below...
Got the new oil pressure switch installed today. Got it from the Chrysler store on Amazon, so it's OE.
For anyone doing this, I pulled it off using a deep 27mm impact socket with a 1/2" ratchet. You don't need a special slotted socket as the wire is attached to the harness, not the sender. Be very sparing with the torque esp when using a large wrench like I did. It's a lot of leverage on that small threaded tip. I'd be in a world of hurt if that broke off. Very tight area to work, being underneath on a 4.7.
There is another oil port nearby which has a bung with a hex head in it. It's to the right just around the corner from your stripped port. Maybe you can use that port instead and just weld the stripped port shut. Not sure the JB weld or other stuff will stand up to oil over time and it will probably crack on you. Even if you have to rethread, I'd fill it with a welder first.
Last edited by Dodgevity; Feb 1, 2024 at 12:06 PM.
Stripped Oil Pressure Switch Advice
