Is there anything you shouldn’t use an impact to remove? That it might cause damage from how hard it hits?
It's totally situational. It also depends mostly on how angry you are. Sometimes the sudden impact will loosen a fastener with less damage than slowly-applied force, and sometimes...not.
Broken fasteners are just a fact of life; and sometimes a person might deliberately break a bolt rather than spend hours trying to nurse it out.
If you cut the wires on a stuck o2 sensor can you put an impact to remove or could that cause more damage to the bung thread?
An impact wrench can absolutely be used, if you can get the tooling in to access it. What damage that causes--
if any--is situational, as described above. Sometimes it works, sometimes it causes damage.
I'm gonna go with impact out of the gate on these, after soaking them for 24 hours.
O2 sensors are sealed to the bung with a crush-washer, exactly like gasketed spark plugs. It is a TOTAL waste of time, money, effort, and enthusiasm to "soak" an O2 sensor, because if hot exhaust gas can't get OUT, no liquid lube can get in to do any good.
Might make a lovely stain on the concrete where it drips off, though.
If you loosen the sensor and then spray it with penetrating oil, the oil can get into the threads...but the hard work of getting it un-seized is already done so you don't really need the penetrant.
You can buy a specific socket so you don't have to clip the wire.
Yes. Those sockets with the slot in the side are GREAT for INSTALLING O2 sensors. The split on the side makes them weak, prone to slipping, which rounds-off the hex wrenching surface. But putting the sensor IN doesn't require a lot of torque.
If the O2 sensor isn't seized, they may work OK for removal. I've had "some" success with them. The tough sensors will require a wrench that is not split on the side. I bought a Wright 4928 7/8 deep impact socket for O2 removal. The Wright brand socket is broached all the way down, there's room inside the socket for the body of the O2 sensor (but not the wires attached.) Most brands of impact sockets are only partially-broached, you'd have to bust off the ceramic body of the socket to make those work.
Issue with an impact on an O2 is the shock can break the heater circuit inside. So if you're reusing it, I would advise trying that last.
Given the difficulty of removing most O2 sensors (by the time I get to them, they've usually been neglected for years if not decades) I've never re-used a sensor. So ANYTHING that gets the sensor out without too much damage to the female threads in the exhaust (I have several styles of thread restoration tools one of which is
usually needed; sometimes the female threads are so wrecked that the whole pipe or casting has to be scrapped.
Worst O2 sensor I ever removed came out of the left exhaust manifold of a Hemi Charger owned by a guy my wife worked with. The "shop" he took it to pushed the car outside when they couldn't get the sensor out. My 3/4" impact wouldn't spin it out--although the extension length and U-joint angle needed would have eaten a lot of torque. We ended up with a 24" 1/2" drive ratchet, a 30-inch-effective length cheater pipe, and
two guys pushing on it through an 18 or 24 inch extension and U-joint. Once it popped free, it spun out with zero damage to the exhaust manifold threads. I was really surprised.