The plug in for the 02 sensor on my friends 89 Ford van 4x4 is melted together. Is it possible to splice the wires together with a new sensor? Or do I have to make a trip to the happy place, (junk yard)?

 

Yes, you can splice the wires, but you should also solder the wire connections. Since O2 voltages are so low, you might get a voltage loss with just a twisted splice.

A better solution would be to splice in a new connector. However, you should also solder the connector splices, for the same reason.

 

...and heat shrink (rather than tape) each splice to keep out moisture and crud. Electrical tape will only hold for so long on a splice made so close to a part of the wiring harness that gets sprayed with road grime on a regular basis.

 

Thanks guys for the info. I will defenitly solder it if it comes to that. It's my bosses truck so have to do a good job LOL.