catalytic convertor

[cpegram]

Well...went to Ford for a check engine light...they said O2 sensor and possibly catalytic convertor...the cat alone was $700 not including labor...so I got the O2 sensor changed out and the light went off. About 2 months later the light came on again....I figure its the cat. SO....check with Pep Boys, Autozone, Oreilly and NAPA....all they sell are single cats...but my 96 needs a dual convertor assembly...triangular flange off the manifold in the front...two cats...then a donut....
and noone carries the assembly. So I head to the muffler shop and they can't do it....they say the 96+ explorer has a different kind of cat assembly that can only be replaced as a unit..they can't get em and won't talk just fabricating some kind of replacement.

I did a search here....found a suggestion about a high flow unit for a 96 bronco....does anyone KNOW if this will fit?
Or does anyone have any other suggestions?

 

[shawnbru]

Cats

I had the same problem in my 91 Explorer. I replaced the O2 sensor and the problem went away. It eventually came back and the Cat was bad so I punched the thing out since I live in Michigan and there is no emissions.

I would recommend hooking up with a diagnostic computer to put on the ECM and have the error codes read out before spending any real money. A Haynes manual can tell you how to do this with just a voltmeter. Yes, you have to look up the codes or you could just buy a digital one for $150+ that tells you the codes.

Summit Racing Equipment sells a high flow double cat that is bolt in for approx. $120 last time I checked.
Hope this helps

 

[jimbo74]

will a bad cat show bad o2 sensor readings on acode reader? or if the codes say bad o2 is it just a bad o2?

 

[cpegram]

I need to buy a code reader but wasn't sure which one to get. You can't use the regular OBD port reader, they changed after 95 to a different type diagnostic port.
There are emissions requirements here in Texas....I was thinking of punching it out but I figured it would blow my emissions readings.
As far as the O2 sensor goes...I'm just going on what Ford told me....when they replaced it they said that the probable cause for the readings they were getting was a bad cat....
Since I know nothing about these engines (I prefer to work on my 68 Mustang or my 71 F100) I am kinda at the mercy of the experts....

 

[Robert]

Either a bad converter or a bad O2 sensor will show up as an O2 code. It takes someone who knows how to interpret the codes to determine which one it is. There are plenty of people here that could give you a good idea as to where to start once you get the codes read. Just because your check engine light is on, it doesn't automatically mean you have a bad O2 sensor or catalytic converter. A bad gas cap can also cause it to come on along with a hundred other things. How many miles are on your Explorer?

 

[drnaline]

Pot of Beans

The shop you went to must be lazy. Any body worth a pot of beans should be able to do it no mater what. Alot of shops will tell you have to replace it as an assembly and its not true. If you have torches, Chopsaw, mig welder and a lift, any thing is possible. I'd look for another shop. If it is a cat I couldn't see paying more than 170.00 to 230.00 period with a fifty thousand mile warrantee.

 

[cpegram]

The truck has 114,000 miles on it. What was said about the guy not wanting to mess with making one up, that could be a possibility. I was wondering whether I needed to check with some more shops about making one up. This guy did contact 3 of his suppliers, and had a long conversation with the first one about the differences in the 96 cat to the earlier models. I got the impression that they might be different types of cats...
I can go to Oreilly and NAPA and get a pair of single fit-all type cats that they list for my truck.
As far as Summit goes...the only ones I can find end with 1995....although they look identical to what I have.
I am almost tempted to buy either the one for the explorer that Summit has and find a way to make it work, or maybe even try the one for the ranger I mentioned earlier......
I would rather have the entire system redone around a replacement cat than spend $700 on the cat alone.

 

[Ross-N-Chicago]

cat

summit has the dual for $152.99
part # CTO 9522 as of Dec 2001

 

[drnaline]

converters

There are basically two different kinds of converters. Two ways and three ways. Both of them can come with or without an air tube. The difference between the two are are in the ceramic honeycomb. Converters have an array of precious metals (platinum, rodium ect). All converters have two honeycombs, one front one back, air tube in the middle if it has one. Front honeycomb it to burn the unburned fuel, the second with the help of air turns carbon monoxide into carbon dioxcide( more enviro friendly). Both need a running temp between 1600 to 2300 degrees for proper function.
There are only two manufactuers of honeycombs in the USA. No mater who you get it from it came from one of them. From there exhaust companies, including O.E.M. manufacters buy these honeycombs and make cases for varios applications then to the end user.
I own an exhaust shop and I pay on average between 40.00 to 60.00 dallars a converter. And average about 170.00 retale, installed.
Converters used to be the bad boy for along time. But was in reason for the way they were designed. Now adays theres not much reason to take them off. Theres not that much difference now and in some cases they use converters as a tuning device for the torque peak on a stock and racing applications. Would you rather have a converter or muffler. If you dont mind a little sound I think trucks sound better with no muffler and stock cats. Sounds good on my truck.

 

[JoshC]

cpegram--i checked that converter out on summit. It does look like the one i have on mine, which is probably the same as you have on yours and the 3 bolt pattern on the front is different on the 95 and down. My dad's 2000 is the same as a 95, not real sure what the heck they were doing at ford, but it's different. I was about to order it like you said until i noticed the bolt pattern. If you can find one, i'll get one too!!

Happy trails!!

 

[JOSEPHOUYSON]

I hope this isnt to late

Well I hope you didnt spend any mony on this issue. Fords do this alot, every newer modle that I can think of. Yes your sensor was bad, no it shouldnt need to be replaced again. Sometimes on fords and especialy on explorers if you have a high flow exhaust system the chech engine light comes on. If your cat went bad it may have actualy increased the flow of your exhaust. I experienced the same problem. Nothing is wrong with your car even though the check engine is on. Just watch the other gages closely, as you will be unaware of other problems that could occur. Good luck

 

[cpegram]

The summit CTO 9522 is for 95 and down, and JOT17 noted a different bolt pattern on the flange, so that one is out (unless I bought it and torched off the old flange and welded it on to the new one, but I'm not that desparate yet).
I currently am running a stock system, and don't really care if it changes or stays stock, as long as it doesn't cost too much.
My O2 sensor went out, they replaced it...now the check engine light is on.....and the engine is running a bit rough when it's cold...
Do you all feel that the problem is the sensor itself or the convertor? Since Ford said intially that the probable cause of the check engine light was the convertor...but I figure that was just a guess on their part...
I figure now the rough running is the computer trying to compensate for the bad reading of the O2 sensor...does that make sense?

 

[88vert]

Whoul it hurt to have the cat taken off,and a straight pipe put in there.Thanks Brad in iowa

 

[JoshC]

Brad, they say the when you take off the cats that you loose back pressure which equals low end torque, but i didn't care because i wanted the extra sound, so i gutted mine, now i wish that i didn't. You wouldn't believe the loss of low end i lost due to that. But it does sound good with my flowmaster, so it depends on what you want!

Happy trails!!

 

[drnaline]

Torch it

If your gonna try it yourself I wouldn't use a torch. Too hard to cut. Use a sawsall to cut it, and save yourself alot of grief.

 

[Robert]

cpegram -- Until you get the codes read everything anyone posts here will only be a guess. Guesses can cost you a lot of money. Either try and have Autozone scan the codes for free (many people have been successful) or try some place like Jiffy Lube. The one by my house has "OBD-II diagnostic scan $19.99" on their big sign out front. If someone guesses that it is your $700 catalytic converter and it turns out to be a bad $10 gas cap, you are going to regret asking for guesses. Both of these items (along with a hundred others) can cause your check engine light to come on.