I have a 1994 Explorer XLT with 191000 miles on it.

When it is hotter outside, the cat rattles excessively and I get a sulfur/bad smell. The battery guage fluctuates excessively, and the engine feels/sound like it is going to cut off, but it never does.

I recently replaced the muffler and had the fuel enjection system cleaned.

Any suggestions?

Have you checked the fuel pressure regulator?The 02 sensors are probally shot too,maybe clogged cat:(

Has the truck had it's tune ups like it should? Is your check engine light on? You O2 sensors may be bad and plugged up the cat. This would give you a sulfur smell. Or the cat may just be plugged due to mileage, or may have broken off inside. The batterty gauge is fluctuating because the rpm's are too low due to the motor nearly stalling.

Have you checked the fuel pressure regulator? I forgot about that, I'd get that checked for sure.

Thanks. I will let you all know how it went.

The smell and the gague fluctuation sound exactly like what happened to my 94 xlt when the battery was toast. New battery, now it works fine. :)

mine would do the same thing, took awhile searching here and trying to track down what was wrong, it lead me to the cat, so to see if that was truely the problem I took it off and "gutted" it and now it works fine. Fortunately we do not have emissions of any sort here in my part of Indiana so I do not have to get a replacement cat till one day when we do.

it really could be any one of a number of things, good luck