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To run cleanly and efficiently, today’s heavy-duty diesel vehicles rely on a complex emissions system. A critical input to the diesel emissions system is the temperature of the exhaust gas, measured by the EGT sensor. Too cool and the system doesn’t reach optimum efficiency. Too hot and it runs the risk of self-destruction. Clearly, a damaged EGT sensor is not to be ignored.

EGT sensors typically sit in the hottest part of the exhaust system, either the diesel catalyst or the exhaust downpipe, where they’re exposed to high temperatures and corrosive gasses. The cycles of extreme heating followed by cooling, combined with exposure to the elements underneath the vehicle, can make it difficult to remove the sensor from its mount.

One solution – certainly the most expensive – is to replace the entire diesel catalyst with a new part. This can run into the thousands of dollars for the part alone just to replace a $50 sensor! A better solution is to replace just the damaged sensor bung, but removing the old one often damages the catalyst housing, making for a questionable repair.

Dorman has solved the problem of replacing a damaged bung with its line of OE FIX EGT bung repair kits, which include not only a new application-specific sensor mount, but also a bung mounting plate that can be welded in place to repair any damage to the catalyst housing during removal of the old bung.

Both parts are made of stainless steel to reduce the opportunities for future corrosion. A qualified repair shop can make the repair in less than an hour once the catalyst is off the vehicle, saving thousands of dollars compared to replacing the entire catalyst assembly.

To simplify ordering, all our EGT sensors now include a replacement bung and mounting plate, just in case you should run into this problem unexpectedly. We also offer the bung repair kits separately for convenience.