This procedure covers the removal and replacement of the downstream oxygen sensor(s) on the 2011-2014 Ford F-150 3.5L EcoBoost engine, located after the catalytic converters in the exhaust system.

Warnings

Tools required

Parts

• Downstream oxygen sensor × 1 — Use OEM Motorcraft DY1161 or equivalent

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow exhaust system to cool completely (minimum 45 minutes after engine shutdown)
3. Raise front of vehicle and support securely on jack stands rated for vehicle weight
4. Locate downstream oxygen sensor on the exhaust pipe after the catalytic converter (passenger or driver side depending on which sensor is being replaced)
5. Spray sensor threads with penetrating oil if sensor has high mileage and allow 10-15 minutes to soak

Procedure

1. 1

   Disconnect oxygen sensor electrical connector
   Locate the oxygen sensor wiring harness connector approximately 12-18 inches from the sensor itself. Press the release tab and carefully disconnect the electrical connector. If connector is corroded or stuck, gently wiggle while pulling to avoid breaking the lock tab.
2. 2

   Free the sensor wire from retention clips
   Trace the oxygen sensor wire from the sensor to the connector and release it from any wire loom clips or heat shield brackets along the exhaust system. This provides slack for sensor removal and prevents damage to the wiring harness.
3. 3

   Remove the downstream oxygen sensor
   Using a 22mm oxygen sensor socket with the ratchet and extension, turn the sensor counterclockwise to remove. The sensor socket has a slot to allow the wire to pass through. If the sensor is seized, apply additional penetrating oil and allow more soak time. Apply steady pressure; do not use excessive force that could strip the bung threads.
4. 4

   Clean the oxygen sensor bung
   With the old sensor removed, use a wire brush to clean the threads inside the exhaust bung. Remove any carbon deposits, rust, or old anti-seize compound. Ensure threads are clean and undamaged to allow proper seating of the new sensor.
5. 5

   Prepare the new oxygen sensor
   Apply a thin, even coat of high-temperature anti-seize compound to the threads of the new oxygen sensor. Apply ONLY to the threads, keeping anti-seize away from the sensor tip to prevent contamination. Do not over-apply; excess compound can affect sensor performance.
6. 6

   Install the new oxygen sensor
   Thread the new oxygen sensor into the exhaust bung by hand, ensuring the wire routes properly and does not contact hot exhaust components. Hand-tighten until firmly seated, then use the torque wrench and oxygen sensor socket to tighten to specification. Verify the sensor is fully seated and not cross-threaded.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
7. 7

   Route and secure sensor wiring
   Route the oxygen sensor wire along the exhaust system following the original path. Secure the wire in all original retention clips and brackets, ensuring adequate clearance from hot exhaust components and moving parts. The wire should have slight slack but not hang loosely.
8. 8

   Reconnect electrical connector
   Connect the oxygen sensor electrical connector firmly until the lock tab clicks into place. Gently tug on the connection to verify it is secure. Ensure no moisture or debris is present in the connector that could cause electrical issues.

Reassembly

1. Verify all wire retention clips are properly engaged and the sensor wire has adequate clearance from exhaust and suspension components
2. Lower vehicle from jack stands and remove jack
3. If both downstream sensors were replaced, verify both electrical connections are secure

Verification

• Start the engine and verify no exhaust leaks are present at the oxygen sensor location
• Allow engine to reach operating temperature and verify the check engine light is not illuminated
• Use an OBD-II scanner to verify oxygen sensor readiness monitors are functioning and no diagnostic codes are present
• Perform a short test drive (5-10 minutes) and re-check for exhaust leaks and proper sensor operation
• Verify the oxygen sensor voltage is switching normally using a scan tool (typically 0.1-0.9 volts oscillating)

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