I have a set of bbk headers. When I installed the o2's in these, it was before I put them in.

Looking at the o2 sensor on the passenger side it seems as if as I'm twisting it out, it will hit the firewall.

How is this sensor replaced with these headers? It's in the worst possible place.

 

I can't help you with that, but I wouldn't be surprised. Make sure BEFORE you put it all back together. The BBK's I bought for my 93 had the EGR pipe welded so it would be inside the heater box. I had to heat and bend the hell out of it to make them work. I emailed BBK, even sent them pics showing how far off the pipe was, and they could care less. The headers sucked, the customer service sucked, so no more $$$ of mine is going to their company for anything, even if their other parts are good.

 

I agree, these headers are garbage. I was able to replace the o2 but again the wires out the top are right but up against the firewall and will without a doubt eventually break from the stress. I tried to dent the firewall in a little and that helped a tad.

I typically do not buy BBK because I don't like their stuff for the 4th gens but I got a steal on these headers and Y pipe so I took it.

 

Now that I thought about it, I had to remove a heat shield under the floor/firewall area on the pass.side to get enough clearance for the O2 sensor. I doubt they ever tried their own product on a real car. I'd be embarrassed to put my name on them, that's for sure.

 

I had a set of BBK's on my first LT1 (94 Z28) but didn't have to mess with them much (bought the car with them on)

Shorty's defintely suck in terms of clearance for o2s, plugs, etc. My Eldebrock TES headers were also a bitch to get off my '97 SS when I swapped them out for Pacesetter LTs.