**UPDATE: My cats are okay...the Dealer just tried to screw my over! See Post #23 for more info.**


Ok, so while we are on the subject of catalytic converters failing or being stolen, I’ve got an issue w/ mine; thought I’d seek some YT advice.
Since Feb, a baffle has broken inside the 2nd cat on my 4Runner. It’s not throwing any codes, but it’s annoying as hell to hear during acceleration. Gives me a headache now and then.

Is the best possible solution to cut the cat out, remove the loose baffle and just weld the cat back up? Dealer wants $1,118.00 for a new cat, so that option is out. I’d prefer NOT to go w/ an aftermarket cat, so no go there either.

I know for a fact I can get a new OEM cat for only $300 installed (part of the Govt's "Go Green" campaign currenly enforce), but I first have to prove that my oem cat will fail an emission test. Lasted tested 2 months ago, it passed w/ flying colors.

Thoughts?

 

What baffle are you refering to? As far as I remember, there is no baffle in there. If something is rattling around, your cat is shot.

 

Well maybe not a baffle per se, but some of the honeycomb material inside. I can tap it w/ a hammer and hear the stuff rattle around. Obviously it rattles much louder when accelerating.

 

yea your cat is toast...........

 

The "honeycomb" material IS the catalyst. Your cat is junk, you cannot simply "fix it" you need to replace the cat, and also figure out what is causing your cat to burn out in the first place!

 

^x2 on the cat being bad. As well as the honeycomb, there are rings inside of there that are barely tac welded in there. When mine went bad these wussy tacks rotted and those rings were rattlin' around in there...very annoying. Not only that but if your honeycomb is at the crumbling point, if it's anything like mine, that honeycomb will come out the tailpipe.

I had a bad sensor which was causing the cat to work MUCH harder, and eventually the codes were thrown and the cat failed. Just a matter of time now, but if I recall the idiot light would come on for about a week, and then be off for months...

I ended up going with a high flow cat (magnaflow) and I haven't had any issues for over a year now...

 

Well, I did figure it was toast, but again, my truck still passes the emissions test w/ flying colors....and it has sound like this for quite some time. I keep waiting for a code to be thrown, but it has yet to happen. Therefore, until I fail the emisson test or a code is thrown, is there a real a reason to have it replaced other than the fact it's just noisey?

And since it has failed, why not just remove it, clean out the loose material inside and weld it back up? I mean, it could be the tac welds that have come loose and are rattling around.

Worst comes to worse, I may just have to go w/ Magnaflow. It's just irritating that the cat has obviously failed, yet I continue to have the cleanest emmisions around.

 

my Magnaflow cost me about $70...and why weld a cat back up w/ no guts...? It would essentially be straight piped...and then most certainly won't pass emissions.

When my cat went bad I saw a slight decrease in mpg...not sure if this matters to you or not, but after a new cat and O2, back up to good fuel economy...

 

The only reason I wanted to remove it, clean it out and weld it back up was cost. Again, it's obviously toast, yet I still pass the emission test.

Guess I'm just a bit optimistic about aftermarket cats...seems like I always read about them throwing a code. I may look into the Mags today though.

And is it safe to assume my 02 sen is still good since my 4Runner has yet to throw any codes?

 

have your cat stolen.....

 

lol...yet I've considered that as of late. Just need to stash the sawzall at a friend's house I guess.

 

Does Magnaflow not offer a cat for a '02 4Runner?? Every site I come across only offers a Magnaflow front cat, but not the 2nd cat...Any reason why a magnaflow cat that fits a '99 or '00 4Runner would not fit my '02?

This site has a Mag cat for a '00 4Runner for only $66...yet not one for mine: http://www.magnaflowcatalyticconvert...tion=0&page=10.

However, Eastern Cat offers a cat for only $78 specifically for my '02...just never heard of Eastern before:
http://www.thepartsbin.com/catalog/?...ota&md=4Runner

 

Some 2000-2002 MR2 Spyders had pre-cat and main cat failures. When the honeycomb failed it partially restricted exhaust flow, created back pressure all the way into the cylinders, collapsed the oil rings allowing massive blowby and before the owner realized the oil loss, roasted little 1ZZ's. They never threw codes before grenading.

I'd replace the cat ASAP.

 

I'm open to brand suggestions

 

Sorry, I've never replaced a cat. Luckily, bad cat (low efficiency) codes from the past were solved with new O² sensors.

 

I may just go ahead and get it...it's worth a shot.

 

I think you will be fine welding one of those up. I don't think it will throw a code. Like I said, I have that setup and it's been over a year and I'm still going strong.

 

Sounds like your 4runner came from the Republic of California. You might try a search on CA cats. They are different from the ones the rest of the world uses.

 

That is correct.

 

Got one on order