Jeep Strokers

Specs: 1991 Comanche, 4.6L Hesco crate stroker w. Mike Leach header.

My O2 sensor is due for replacement, overdue actually. I can not use the factory recommended NGK sensor since the harness is about 6" too short due to the header bung placement. I know I could use an extension cable but would rather not. I have a Bosch O2 sensor on it now and used it only because it had a longer harness. IIRC it was for a Grand Cherokee. I'd prefer to use an NGK sensor if I could find one with the longer harness. Anyone have a recommendation and/or part number for my application? Thanks all!

EDIT: Do not need a wide band unit.

they make O2 sensor extension harnesses. You could cut the harness side and extend the wiring that way too.

I tried extending the O2 sensor harness once with mixed results on a Bosch O2 sensor. The harness wires are coated thermocouple wire and didn't take solder well at all. I've read that the best way to do this is to use crimped butt connectors but have not tried it. I'd much rather use one with a 6" longer harness than stock if possible and was hoping someone knew of one that would be correct for our engines.

Are you trying to extend the O2 sensor wires and not the vehicle harness wires?

Comanche91 wrote:The harness wires are coated thermocouple wire and didn't take solder well at all.

That is quite odd. I DID extend my wires on my 95 Grand Cherokee. I cut a an O2 cable harness off an XJ at Pick and Pull (no ZJs at that time), and I had no problems soldering it in to extend mine. Just had to watch the wire colors, as there were minor differences. I have the same Mike Leach header, and it is a tight stretch as you have found. Are you sure you were using rosin core solder? Worked fine for me, no issues.

Good luck with it.

Jerry

Sharp Rock wrote:

Comanche91 wrote:The harness wires are coated thermocouple wire and didn't take solder well at all.

That is quite odd. I DID extend my wires on my 95 Grand Cherokee. I cut a an O2 cable harness off an XJ at Pick and Pull (no ZJs at that time), and I had no problems soldering it in to extend mine. Just had to watch the wire colors, as there were minor differences. I have the same Mike Leach header, and it is a tight stretch as you have found. Are you sure you were using rosin core solder? Worked fine for me, no issues.

Good luck with it.

Jerry

Yes, I thought it was odd too. And yes, rosin core solder. Maybe it's a Bosch thing, but the wires did not take solder well at all because of the coating on the wires.

EDIT: It looks like the NTK 23023 O2 sensor will work; the harness is about 4" longer. Just ordered it from Rock Auto. It's for the 94-95 XJ 4.0L upstream sensor and other Mopars so it should be fine.

Continuing, I got the NTK 23023 O2 sensor on with no problems with it's 4-pin connector located in the stock location; plenty of clearance from the exhaust header now. When I installed my 01 intake manifold I routed the vehicle O2 wiring harness down from the top of the engine wire cover through an split between the intake's runners. Even though I shielded the wires with thermal insulation, I noticed there was evidence of cooking where it passed down through the manifold, so I'm going to redo it. For those using the late model intake, how did you route this harness down to the O2 connector? Better yet, how did the factory do it? I don't have one here to check. I didn't realize the intake manifold got so hot, and I do have shielding between the exhaust header and intake manifold. A pic would be great. Thanks!