catalytic converter

[bigfish02ut]

Hi all, I'm hoping you can give me a little perspective. I have a '96 4.0 V6 Eddie Bauer with 85K miles. Couple of months back the check engine light came on and stayed on; took it to the dealer and they said the codes showed a bad CAT sensor; replaced the sensor and the light went off. Couple of weeks ago, I came off the NC beach after 4-wheeling and the check engine light came on again; took it in to the dealer and they now say that the entire Catalytic Converter needs to be replaced, to the tune of $1000 for the repair. Is there anything else I can do to avoid this repair, or can I get a used Cat converter and have it welded in the exhaust pipe to clear the fault and save some $$? Any suggestions would be appreciated. Also, what regular maintenance items would you suggest for 85K miles other than plugs, wires, air filter, belt check etc. The truck runs very well with the exception of this problem and I'd like to keep it a while longer. Thanks in advance.

 

[BradE.]

What code are they getting now?

 

[williecume]

go to a muffler shop and have them install new cats. they will be much cheaper there. if i'm not mistaken get some high flow cats that are 2.5".

the shops i have been to seem to have dayco brand cats. i think those will work just fine.

i sure some of the other guys will inform you if my answer is wrong.

 

[410Fortune]

Masking the real problem.

If your cat is clogged at 85K miles there is a reason,the reason a cat gets clogged is usually raw fuel. If you are dumping raw fuel then it's likely a 02 sensor or MAS meter.

Replacing the cat(s) at a local shop will cost about $200 total. I would get a second opinion, find out what code is coming when that light is on up and then post it here.

Yopucan also have a flow test done on your exhaust to find out if that sucker really is clogged up. Sounds to me like they are just pulling a code and jumping to a conclusion if you ask me, then you drop $1000 to have it fixed, 6 months later your back again with another CEL because the same fuel problem still exists......

 

[bigfish02ut]

They didn't tell me what the code was, just that the CAT was testing bad and needed to be replaced. I have my doubts about this Ford dealership's honesty (and about the whole check engine light to begin with!). Everytime I go in there, they try to stick me for $500 to a grand in repairs and this truck runs great.

 

[BradE.]

I would take it elsewhere and have it looked at. Also, if you can find out the code lets us know. I can look it up and see what it says. I have a copy of the Ford PowerTrain Diagnostic Manual (Basically says what every code means and what to do about it.)

 

[bigfish02ut]

Thanks, I have service scheduled at another Ford dealer this weekend and will post the code and their diagnosis as soon as I have it.

 

[bigfish02ut]

Hi Again-

I have had all the major service done on the vehicle now. The second opinion, from a second Ford dealer, was that the catalytic converter does indeed need to be replaced. The error code they gave me from the diagnostic was P0420. Can anybody help with what that code refers to and how to proceed from here? I'm currently planning on taking the truck to Midas to have the cat converter replaced and the check engine light replaced. Thanks!

 

[BradE.]

P0420= Catalyst System Efficiency Below Threshold (Bank 1)

Will look up more when I get a chance.

 

[bigfish02ut]

Thanks Brad. BTW, I called Midas to check on the replacement cost for the CAT and they say they don't stock the part and would have to order it from Ford, so I'd be better off getting it done at the dealership. Any thoughts on a repair shop or chain that might be able to get the part and handle the repair? I'm in Northern Virginia.

 

[BradE.]

I just looked up the code in my factory manual, the diagnostic routine for that code is massive (Around 10 pages). There are any number of things that could cause that code. I hope the shop exhausted all options before deciding you need a new cat.

You could try www.fordpartsnetwork.com and order the part and then perhaps take it to Midas and have them install it. Would still probably be cheaper than paying the dealer mega $$$$.

 

[aldive]

Originally posted by bigfish02ut
I have my doubts about this Ford dealership's honesty

Delership and honesty? What an oxymoron.

Take it to a good independent repair facility and avoil all dealerships.

Good luck.....

 

[james t]

never, ever, never, ever never buy a stock replacement type cat. you are just wasting your money. you can get high-flow aftermarket cats from $70-150. you would come out much cheaper buying 2 high flow cats, and having independant shop (NOT midas) cut yours off and run just 2 (one per side).

check out www.summitracing.com

also, many independant shops have cheaper than factory type high flow cats in stock. your Midas shop was lazy, and must not have wanted to do any welding that day.

 

[bigfish02ut]

and the aftermarket high flow cats would increase power I suppose? I got an estimate from an independent repair shop of $850 for the replacement; they told me that my truck has 4 cats, but I only see two in the exhaust pipe. Is it me, or is there a serious lack of qualified repair shops out there?

 

[bigfish02ut]

An additional note is that the check engine light came on just as I was coming off the NC beach after off-roading. I have a feeling that this fault may be due to physical damage to the cat rather than any engine problem, since there's a fairly sizable dent on the front of the first inline cat (I suppose this is actually the pre-cat?).

 

[james t]

if you go with factory style, then yes you will need 4. this is how ford did it. you can get 2 highflows and it will work (pass emissions/be legal/wont screw up computer). just have a shop cut them all off and weld on 2 aftermarket ones.

 

[bigfish02ut]

Resolution of my catalytic converter issue: I decided that if the truck would still pass emissions and was running fine, I would skip the cat replacement to save $$, regardless of the check engine light. I took it into a local repair shop to have the emissions done, which the truck passed with no problem and the shop reset the CEL for me, no charge. It has not come back on again after a week or driving. I think that the fault was triggered during off-roading when the Cat may have been dinged up a bit, but since then no new fault has been registered so the light stays off. Thanks for the chat, it was helpful.

 

[Oakey_Truck]

thats what I would have done. Actually I was just told that mine is, qoute "all eatin' up inside". Who knows, only reason I ask is becuase I heard a rattling sounds at mid RPM while accelerating. Just had thermostate replaced, maybe that will help....who knows. 2nd one in a year. BAH

 

[dogfriend]

Originally posted by Oakey_Truck
thats what I would have done. Actually I was just told that mine is, qoute "all eatin' up inside". Who knows, only reason I ask is becuase I heard a rattling sounds at mid RPM while accelerating. Just had thermostate replaced, maybe that will help....who knows. 2nd one in a year. BAH

I had this problem (rattling or buzzing while accelerating) on my 89 Ford Ranger. It was caused by a heat shield on the catayltic converter. I fixed it by getting the largest stainless steel hose clamp I could find and clamping it around the shield and converter.

You might want to check yours to see if you have a similar problem with a heat shield that is loose.