Broken Crankshaft Position Sensor

I know I’m not the only one who’s done it. A Google search for “crank position sensor broken off in engine” and it’s pages upon pages of results are testament to a poor design that has pissed off many a mechanic. The sensor itself doesn’t fill up the entire bore in the engine block where it is installed. This leaves just enough room for a ring of rust to build up behind it, preventing it from being removed. Couple that fact, with the cheap, plastic construction of the sensor body, and you have a recipe for disaster. Specifically, the damned sensor body snapped after I tried for about an hour to coax it out of it’s hole. Continue reading