Heat it with a torch and be done with it.

 

Well damn it all. I am just going to buy headers and leave that bastard on there.

 

Perfect! Always use a r/r job to justify a mod to the woman if you can.

 

It's possible to damage the threads if the sensor is practically welded into the bung. If the threads do get damaged you can use a spark plug hole thread chaser for a repair.

 

Use a torch on it. Makes it a simple job.

 

Thats the best idea yet!

I know a local guy that has some Pacesetters he is not using

 

Strange, my brother has some pacesetters in town he is not using...

Too bad I just spent 2k on a tranny/converter.

 

Thats good info on the spark chaser. When I pulled off my exhaust this last time, I had cut it in pieces. (I replaced it front to back so no big deal) I removed the o2 sensor in a vice with a map gas torch. (burns hotter than butane)
Even then It still messed the threads up on the way out. It did not matter at that point since the exhaust got junked. I guess if the sensor sits in there long enough it can fuse with the exhaust.The reason I kept mine, was for the new headers. ( I heard the coating can foul up new o2's)

Exhaust rusts over time, and those threads will eventually just rust up completely.

I saw in the rebuilding LT1 book, that they used parafin wax on stubborn bolts. (heat up the part then cover with wax) It is supposed to melt into the threads. I wonder if this is a good thing to try?

 

If you don't want to try and save the sensor, cut the pigtail off, and use a 6-point box wrench- Like everyone has said, heat is your friend. I have had good luck just letting the engine run for ten minutes, but the next step up would be MAPP gas- similar to propane, but hotter- heat the pipe around the joint, not the sensor

Recommend using AC-Delco for the replacement- I think their tolerances are a little tighter-