I was wondering if it would be smart to take pliers, break the sensor and vice grip the screws out. Any thoughts?
Try using a screw extractor...first use a punch and hit the head of the bolts with a few solid shots. not to hard...spray it with "monkey piss" and use an extractor...If that don't work drill, easy out and Heli-coil will always suffice...Sometimes using a left twist drill bit will remove broken bolts...If you don't have the equipment...take the throttle body to a machine shop and have a professional do it...Pliers and vice grips sounds like "Jeep Abuse" to me...breaking it off would be a mistake...Bet that route takes you to "Jeep Hell"...
i had seen this problem discussed somewhere else on here before and someone had said break the housing. i used a flathead screwdriver and a hammer and started on the outside very gently. then i use a pair of slip joint pliers on the head and it came out. unless you have a stubby dill or want to take the throttle body off there isn't room to get a drill in position to use an easy out.
You can get a GrabIt extractor set for like $10-20...they work really well for stuff like that if you can get a drill back there. One side reams the hole out...then the other side has teeth that grab the reamed out hole as you're running the drill in reverse and once the teeth lock in, it'll screw right out.
"We don't build great brakes because we think you don't know how to drive, we build them for the guy on the road in front of you that doesn't." - Black Magic Brakes