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The 5th generation 2011 Explorer bore similarity to the Explorer America concept's construction, and includes a unibody structure based on the D4 platform.

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Overtightened oil pressure sensor and cracked housing unit

  • Oil pressure sensor housing unit split in half can it be repaired


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By the housing unit, do you mean the hole in the engine block the sensor screws into? If that's the case, I'm afraid you're in bad shape, my friend. Chances are it is not repairable; it has to withstand the pressurized oil and even something like JB weld will probably not hold up against the heat and pressure.

If it's any consolation, you're not the first that this has happened to by a long shot. Here's a whole Reddit thread on that exact same problem.

Block Image

Overtightened oil pressure switch = cracked block. What options do I have? : r/MechanicAdvice

The general consensus from that thread is that you'd have to pull the engine, strip it down, have it cleaned in a hot tank and then you can finally have someone take a TIG welder to it and weld the crack, after which the hole will have to be re-tapped. Some of the opinions expressed felt that unless the engine was some kind of specialty that it wasn't worth the effort, depending on how extensive the crack is (the one they were discussing in the thread was extensive).

It wouldn't hurt for you to take some pictures of your cracked housing and add them to your question so we can get a feel for how bad it might be; who know, maybe we'll have a different opinion but we won't know until we can see.

Adding images to an existing question - iFixit Repair Guide

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