MAP Sensor bolt STUCK - any ideas

[kevaug]

Hi - I was trying to replace my MAP sensor on my 2004 Ram 1500 4.7L

I cleaned out the torx recess with a wire brush & sprayed the bolt down with liquid wrench. I used a T15 torx bit with a low profile ratchet set and it fit perfectly in the limited space that there is between the bolt head and AC compressor. Needles to say I stripped the T15 torx. head. I am confused as the housing it sits in is molded plastic - I assume it is lined with a metal thread and most have corrosion.

So today I took my dremel and cut a slot for a flat blade screwdriver. It fit well. I used liquid wrench and PB Blaster. I cannot budge this tiny bolt.
The screwdriver is at a slight angle due to the mounting leg of the AC compressor.

Would it be OK to dremel out a little arch in the AC mounting leg so the screwdriver can be more head on? Or do you think I should remove the belt and then remove
the 3 AC mounting bolts and move the compressor a bit. Not sure how much wiggle room I will get with hoses still connected and oil fill tube right next to it.

Any suggestions?
Thanks
Kev

 

[Marley]

That's unfortunate, those bolts require minimal Torque.
I personally prefer Kroil for stubborn bolts.

If you end up breaking the head, it's not mandatory that you use a bolt on map sensor.
I ended up using a twist on without issue even though I have 2 obvious bolt threads but I'm dealing with a 5.7.

 

[kevaug]

Thanks thats encouraging in case I snap it. I was wondering if it was really necessary since the other mounting hole doesnt have a bolt it looks like it just a post.

I initially wondered that myself because the vacuum is so great and must really suck in the MAP.

 

[kad]

I had a similar problem on a Jeep Liberty with the V6. I ended up breaking the plastic from around the bolt and then taking a pair of vice grips to it to get leverage.

-K

 

[kevaug]

Thanks K, thats a great idea. I will attempt some more patience today but if not this hopefully would be a solution.

 

[kevaug]

Any chance this bolt is lock tighted in? Can I apply a heat gun to this area or will I damage the plastic intake and plastic MAP sensor?

 

[kevaug]

Well I finally got it. I went out and bought a brass punch and spent 1/2 a day on the light tapping / penetrating oil routine.

My horizontal dremel cut was getting a little worn for my screwdriver so I decided to hand cut a vertical slot using a hacksaw blade.

I then grinded down a screwdriver blade to fit the hacksaw slot. I used the largest screwdriver I could to get the most leverage.

I then removed the AC condenser to give me more of a head on shot at the bolt.

That thing was so tight but eventually it snapped free. Thanks for all the great advice.

 

[kad]

Well I finally got it. I went out and bought a brass punch and spent 1/2 a day on the light tapping / penetrating oil routine.

My horizontal dremel cut was getting a little worn for my screwdriver so I decided to hand cut a vertical slot using a hacksaw blade.

I then grinded down a screwdriver blade to fit the hacksaw slot. I used the largest screwdriver I could to get the most leverage.

I then removed the AC condenser to give me more of a head on shot at the bolt.

That thing was so tight but eventually it snapped free. Thanks for all the great advice.

Glad to hear that you got it out.

-K