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Broken Cat #4734026
04/21/18 10:32 AM
04/21/18 10:32 AM
Joined: Feb 2011
Posts: 2,041
California
Stelth Offline OP
Stelth  Offline OP
Joined: Feb 2011
Posts: 2,041
California
I have a '94 Ram 2500 4x4 truck with a utility bed and pipe rack. Ever since I got it, I've felt like it didn't have enough power. I've never had a Dodge 360 before, but even at a rating of 230 horsepower in an 8800 GVWR truck, I thought it should have a little more juice. Just recently, it began getting worse. I had personally replaced the muffler and a lot of exhaust pipe, so I didn't think that was the problem. Then I began hearing a loud hissing and realized that it was coming from the cat. Pulled out the O2 sensor and stuck a coat hanger wire in there, and could feel things clunking around.

When I did the exhaust, I welded most of it, but up toward the front, I used a clamp where it would have been impossible to weld. Fortunately I was able to get it loose and pull the pipe right behind the cat off. I looked in with a flashlight and saw large chunks of the catalyst inside; for some reason it had broken into pieces. As I was driving, these pieces would move around, and I would get more or less restriction.

I was able to ram a metal stake into these chunks and break them up small enough to blow out by running the engine. Now I have the kind of power I expected, in fact, I have to watch my speed on the freeway, which was not a problem before. smile

I obviously have to replace the cat, any recommendations on a CARB-approved item? Magnaflow makes one, would that be good?


Experts are often wrong, but rarely in doubt.
Re: Broken Cat [Re: Stelth] #4734031
04/21/18 10:36 AM
04/21/18 10:36 AM
Joined: Apr 2017
Posts: 1,125
SF BAY AREA, CA
dogememe Offline
dogememe  Offline
Joined: Apr 2017
Posts: 1,125
SF BAY AREA, CA
Yeah, the Magnaflow ones are fine, we sell them at my job, only problem we ever had was with [censored] quality welds on the direct-fit ones that are part of larger assemblies. Where in Cali are you?

Last edited by Kestas; 04/21/18 01:31 PM. Reason: No need to completely quote the first post in the second post

2010 Ford Escape FWD 2.5 ~90K Miles
Currently: Royal Purple 5W-30, Wix 51348
I prefer Royal Purple, Valvoline, Castrol, and O'Reilly Oils.
Re: Broken Cat [Re: Stelth] #4734035
04/21/18 10:40 AM
04/21/18 10:40 AM
Joined: Sep 2015
Posts: 5,945
Kalifornia Kollective
BrocLuno Offline
BrocLuno  Offline
Joined: Sep 2015
Posts: 5,945
Kalifornia Kollective
So does this CAT have an external air feed (little tube coming in the front side)? If not, any universal fit CAT with the right dimensions will work fine. Weld it in if you can, as they get pretty hot and can work the pipe joints.

But, before I replaced an OEM CAT, I'd take it to a SMOG shop and see what it blows? Just get a "pre-test" and see what the numbers are? If they are good enough, I'd leave well enough alone. I have had two vehicles with gutted CAT's that pass smog fine smile

There is no need to spend money if not needed, and the truck runs well as is ...

Last edited by BrocLuno; 04/21/18 10:41 AM.

Formerly in marine engineering. In an earlier life I owned my own petroleum tank truck, and hauled for the majors and independent's.
Re: Broken Cat [Re: dogememe] #4734052
04/21/18 10:56 AM
04/21/18 10:56 AM
Joined: Feb 2011
Posts: 2,041
California
Stelth Offline OP
Stelth  Offline OP
Joined: Feb 2011
Posts: 2,041
California
Originally Posted By: dogememe
Yeah, the Magnaflow ones are fine, we sell them at my job, only problem we ever had was with [censored] quality welds on the direct-fit ones that are part of larger assemblies. Where in Cali are you?

San Diego area.

Re: Broken Cat [Re: BrocLuno] #4734055
04/21/18 10:58 AM
04/21/18 10:58 AM
Joined: Feb 2011
Posts: 2,041
California
Stelth Offline OP
Stelth  Offline OP
Joined: Feb 2011
Posts: 2,041
California
Originally Posted By: BrocLuno
So does this CAT have an external air feed (little tube coming in the front side)? If not, any universal fit CAT with the right dimensions will work fine. Weld it in if you can, as they get pretty hot and can work the pipe joints.

But, before I replaced an OEM CAT, I'd take it to a SMOG shop and see what it blows? Just get a "pre-test" and see what the numbers are? If they are good enough, I'd leave well enough alone. I have had two vehicles with gutted CAT's that pass smog fine smile

There is no need to spend money if not needed, and the truck runs well as is ...


Doesn't have any external air feed. Doesn't the replacement need a CARB approval number stamped on it?


Experts are often wrong, but rarely in doubt.
Re: Broken Cat [Re: Stelth] #4734060
04/21/18 11:03 AM
04/21/18 11:03 AM
Joined: Jun 2003
Posts: 17,468
Deplorable in apple valley, ca
Chris142 Offline
Chris142  Offline
Joined: Jun 2003
Posts: 17,468
Deplorable in apple valley, ca
Originally Posted By: Stelth
Originally Posted By: BrocLuno
So does this CAT have an external air feed (little tube coming in the front side)? If not, any universal fit CAT with the right dimensions will work fine. Weld it in if you can, as they get pretty hot and can work the pipe joints.

But, before I replaced an OEM CAT, I'd take it to a SMOG shop and see what it blows? Just get a "pre-test" and see what the numbers are? If they are good enough, I'd leave well enough alone. I have had two vehicles with gutted CAT's that pass smog fine smile

There is no need to spend money if not needed, and the truck runs well as is ...


Doesn't have any external air feed. Doesn't the replacement need a CARB approval number stamped on it?
yes it does. And the smog guy will fail it if it has the wrong numbers or no numbers.


02 Wrangler durablend 10w40
87 F250 traveler 15w40
04 Tahoe super-s 10w30
Z400 castrol T 10w40
Can am maveric edge 5w40
57 case tractor 15w40
Re: Broken Cat [Re: Stelth] #4734066
04/21/18 11:12 AM
04/21/18 11:12 AM
Joined: Sep 2015
Posts: 5,945
Kalifornia Kollective
BrocLuno Offline
BrocLuno  Offline
Joined: Sep 2015
Posts: 5,945
Kalifornia Kollective
Ah, but the gutted OEM is fine for visual inspection. So if it blows clean enough, you are good smile


Formerly in marine engineering. In an earlier life I owned my own petroleum tank truck, and hauled for the majors and independent's.
Re: Broken Cat [Re: Stelth] #4734116
04/21/18 12:06 PM
04/21/18 12:06 PM
Joined: Mar 2008
Posts: 6,980
USA
slacktide_bitog Offline
slacktide_bitog  Offline
Joined: Mar 2008
Posts: 6,980
USA
The Magnaflow CARB cat will be fine smile

Re: Broken Cat [Re: Stelth] #4734148
04/21/18 12:45 PM
04/21/18 12:45 PM
Joined: Dec 2017
Posts: 19
GA
dmoses42 Offline
dmoses42  Offline
Joined: Dec 2017
Posts: 19
GA
Oddly enough, I had a similar issue on a 1995 Dodge 1500 I bought new. At about 75,000 miles if I remember correctly, I was headed to work one morning and it acted like it ran out of gas. Let it sit for a couple of minutes and it would start and I could drive about 100 yards. Limped it back home that way, thinking I would have to buy a new fuel pump. At that time, OEM was all you could get, so I had it towed to the dealership to confirm my suspicions. Lo and behold, when I called for the confirmation, they told me that everything in the cat came loose and stopped up the muffler. They told me it was covered under the emissions warranty and replaced the entire exhaust system except for the tailpipe.

Re: Broken Cat [Re: Stelth] #4734157
04/21/18 12:52 PM
04/21/18 12:52 PM
Joined: Aug 2010
Posts: 1,081
pa
benjy Offline
benjy  Offline
Joined: Aug 2010
Posts: 1,081
pa
magnablow stuff is quite pricey + since you can weld possibly a universal fit would work, but don't know about a carb #

Re: Broken Cat [Re: Stelth] #4734195
04/21/18 01:28 PM
04/21/18 01:28 PM
Joined: Feb 2013
Posts: 10,854
Phoenix, AZ
Nick1994 Offline
Nick1994  Offline
Joined: Feb 2013
Posts: 10,854
Phoenix, AZ
My Jeep's catalytic converter broke too, but didn't impact power, just rattled a lot. I put a Magnaflow (non CARB) on it and it's fine.

But I think mine broke from off-roading, it was dented on the bottom whistle


2015 Hyundai Sonata 2.4L 85k Mobil 1 AFE 0w30 & OEM
2000 Toyota Camry 2.2L 230k Valvoline 5w30 & Fram Ultra
1996 Jeep Cherokee 4.0L 147k Mobil 1 HM 10w40 & Fram Ultra
Re: Broken Cat [Re: benjy] #4734203
04/21/18 01:38 PM
04/21/18 01:38 PM
Joined: Jun 2003
Posts: 17,468
Deplorable in apple valley, ca
Chris142 Offline
Chris142  Offline
Joined: Jun 2003
Posts: 17,468
Deplorable in apple valley, ca
Originally Posted By: benjy
magnablow stuff is quite pricey + since you can weld possibly a universal fit would work, but don't know about a carb #
a universal is a smog fail


02 Wrangler durablend 10w40
87 F250 traveler 15w40
04 Tahoe super-s 10w30
Z400 castrol T 10w40
Can am maveric edge 5w40
57 case tractor 15w40
Re: Broken Cat [Re: BrocLuno] #4734219
04/21/18 01:55 PM
04/21/18 01:55 PM
Joined: Dec 2017
Posts: 1,137
US
JLTD Offline
JLTD  Offline
Joined: Dec 2017
Posts: 1,137
US
Originally Posted By: BrocLuno
So does this CAT have an external air feed (little tube coming in the front side)? If not, any universal fit CAT with the right dimensions will work fine. Weld it in if you can, as they get pretty hot and can work the pipe joints.

But, before I replaced an OEM CAT, I'd take it to a SMOG shop and see what it blows? Just get a "pre-test" and see what the numbers are? If they are good enough, I'd leave well enough alone. I have had two vehicles with gutted CAT's that pass smog fine smile

There is no need to spend money if not needed, and the truck runs well as is ...


^this.

My brother had a Dodge V10, drilled out bith CATs and it passed emissions for years until he traded ...


I'm a thickie; assimilate
But 20s have their place

Using AMSOIL

Hers: 2008 Jeep Liberty 138k, SS 5w30/Amsoil

His: 2015 4Runner 41k, OE 5w20/Wix

Re: Broken Cat [Re: Stelth] #4734252
04/21/18 02:18 PM
04/21/18 02:18 PM
Joined: Nov 2006
Posts: 20,083
MA, Mittelfranken.de
Trav Offline
Trav  Offline
Joined: Nov 2006
Posts: 20,083
MA, Mittelfranken.de
No cat monitor, no CEL, cat in place with correct numbers I say give it a try as is. Get the thing good and hot with a good highway drive first.


ASE L1, Master. Deutsch Meisterbrief.
Re: Broken Cat [Re: Stelth] #4734288
04/21/18 02:38 PM
04/21/18 02:38 PM
Joined: Dec 2011
Posts: 340
key largo,fl
henni Offline
henni  Offline
Joined: Dec 2011
Posts: 340
key largo,fl


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