Thanks DD, I was going to try that but thought if I stuff the sensor and still cant get it out I might be in a spot of bother.
I'll go get the vise grips!

soak it with crc and be patient, you'll get there..
mmmmm this wheel feels good... :P

Stop teasing me!!!!!
I want my wheel or I'm gonna have a tanty!!

threeeeee twooooo two and a Hallllllfffffffffffffffff....



mmmmm shiny GT wood wheel.. makes my Thou go fast.. and there a little tear in my eye...:P

OK, wait for it...... tanty NOW!
Oh I spose you missed that, should get a web cam!

Got the sender out, it came out by itself on the second attempt ( I think it was scared after my tanty!)

So uh i had the same issue i used crc and vice grips and the temp sensor just crumbled. im now stuck with half the sensor in the head, the nut wont back in. im panicking really bad now.I have the new sensor to go in but no way of getting the old one out.

Ive got the same problem, I have also tried vice grips and crc. Its a tricky spot to get to with vice grips, but when i did get a good grip on the end part of it that was sticking out it tore away leaving the rest behind and somewhat unreachable. I did manage to get the nut part of it back on though though, then I just ended up buing a new temp gauge and a temp sender adaptor that fits into the top radiator hose.

Have you tried a reverse thread bolt remover? (screw extractor) That might do the job.

I thort about using one of those "easy-out" things,
The bit that is stuck is not threaded and its quite thin, It would probly jst force it to expand outwards and jam up and/or tear it and make it leak.

I'm a bit confused about which part of the sensor you guys are having trouble with, sounds like the inner part is stuck but the outer threaded sleeve is ok? A couple of pics might help here.
Cheers.