Extending oxygen sensor wires for longtube headers - Ford Mustang Forums : Corral.net Mustang Forum
 
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post #1 of 10 Old 12-18-2001, 02:23 PM Thread Starter
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Question Extending oxygen sensor wires for longtube headers

What is the best way?? cut the wires and solder in new ones? I know that Brothers sells and extension kit but it's like $40!! If I solder should I put silicone sealer or something?

Thanks Chuck


93 Hatch, R331 - TFS "Street Heat" Aluminum Heads - S-Trim 15lbs of Boost - Holley Systemax Intake - Anderson Power Pipe - Aeromotive Fuel system - 72 lb injectors - Accel DFI Gen VII - Snow Performance Boost Cooler - 661 RWHP Full interior - 10.70's @ 135 w/ traction issues!!

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post #2 of 10 Old 12-18-2001, 02:32 PM
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I just used some of the same guage wire that the o2's are made of and extended the harness via solder, I placed some shrinktubing on either ends and then taped them and put them in come more of the factory style plastic colvouted tubing.

no problems here, just be sure that you keep them zip tied away from any major heat source. ie: collectors or primary tubes on headers.

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post #3 of 10 Old 12-18-2001, 03:03 PM
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You don't need to cut them. Follow the wires and you'll see that if you simple re-route them you can drop them down the back of the engine and buy yourself enough length that you don't need to extend anything.
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post #4 of 10 Old 12-18-2001, 03:15 PM
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Originally posted by MFE
You don't need to cut them. Follow the wires and you'll see that if you simple re-route them you can drop them down the back of the engine and buy yourself enough length that you don't need to extend anything.
This is how I did mine as well, Its real easy.

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post #5 of 10 Old 12-18-2001, 03:27 PM Thread Starter
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Really..... were did you re-route them?? over the bell housing?

93 Hatch, R331 - TFS "Street Heat" Aluminum Heads - S-Trim 15lbs of Boost - Holley Systemax Intake - Anderson Power Pipe - Aeromotive Fuel system - 72 lb injectors - Accel DFI Gen VII - Snow Performance Boost Cooler - 661 RWHP Full interior - 10.70's @ 135 w/ traction issues!!
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post #6 of 10 Old 12-18-2001, 03:57 PM
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Another option is to buy a couple of replacement O2 sensor pigtails (female) from NAPA (should be around $8 each) and cut the O2 sensor plugs (male) off of some old/dead O2 sensors.

Solder the two together, instant extension harness.

Brian

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post #7 of 10 Old 12-18-2001, 09:24 PM
 
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Like MFE, I re-routed the original harness. Originally it was run at the front of the engine on the same brackets as the starter cable and goes back on each side of the oil pan and connects to the sensors. I detached the harness from the brackets and ran it across the back of the k member using some factory holes and insulated clamps to secure it. This made it long enough to reach both 02 sensors. I also used to more insulated line clamps and bolted them to the 2 lower 5/16" bellhousing bolts holding them away from the exhaust and the ground. I did notice the harness was touching the passenger header where it attaches to the main engine harness under the MAF. So I used anouther insulated line clamp to secure it to the side of the frame away from the header tube. You'll get the idea when you get under there and look at it. This is a much better alternative to cutting up the factory wires.

Another option if your o2's are old. Pepboys sells the high-quality Bosch O2 sensors and 3 different wire lengths are availible. 8" (stock), 12" and 18" I believe. The 18" version should be more than enough to reach with the harness in the original location.

Lastly I would add extra length to the harness. $5 in electrical parts when compared to the $40 for the extenders at Brothers Performance. Ford will sell you the original harness side and O2 side connectors as well so you could make you'r own extenders.
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post #8 of 10 Old 12-19-2001, 12:10 AM
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I rerouted mine...ended up with WAY MORE wire than necessary. I actually had to zip-tie some up so it would stay off the ground.

Once you are under the car....it will look easy to you. TRUST ME....this was my first time w/ longtubes, but they worked great and it was easy!!!
post #9 of 10 Old 12-19-2001, 12:13 AM Thread Starter
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Thanks guys.....I really did'nt want to cut and solder the wires.....I will try re-routing them also.

Thanks again.

~Chuck~

93 Hatch, R331 - TFS "Street Heat" Aluminum Heads - S-Trim 15lbs of Boost - Holley Systemax Intake - Anderson Power Pipe - Aeromotive Fuel system - 72 lb injectors - Accel DFI Gen VII - Snow Performance Boost Cooler - 661 RWHP Full interior - 10.70's @ 135 w/ traction issues!!
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post #10 of 10 Old 12-19-2001, 12:53 AM
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Thumbs up

Either reroute the oxygen sensor harness, or go up to AutoZone and get some new oxygen sensors. They have them in 8.5", 13", and 16.5" lengths.

Look under the "Emission Control (Engine Management)" section here:

http://www.autozone.com/


Last edited by rtz; 12-19-2001 at 12:56 AM.
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