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Posted by oldjag on August 5, 2008, 10:54 pm
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Some welding content...Got a sort of free 2003 V6 Ford Escape a few
months ago. Front brakes were shot and I needed a 20 tons on the press
to remove one of the front rotors from the hub...major rust between
the OD of the hub and the ID of the rotor hat. Bearings in hubs were
shot anyway, so replaced them also. Car has three catalytic
converters. It appears the underbody cat was replaced at some point
with aftermarket part that sort of fit...probably melted due to a
failed coil pack...Major exhaust leak on the rear bank manifold
cat...can was cracked in two places. Had to pull intake manifold,
wiring harness, alternator, under pan, etc. etc to remove. The
substrate looked fine, so I TIG welded up the can with some Inconel
wire and reinstalled. Before putting back the Y pipe, I put a
borescope up the outlet of the front manifold cat..and guess what...
the substrate in the front manifold cat is totally gone. It seems
that there are no aftermarket front manifold cats made for this car,
so I may have to shell out 500+ bucks to the Ford stealer. Just out of
the 80K mile emission warranty too. Local junkyards, (not in CA by the
way), tell me they are not allowed by law to sell perfectly good used
units....they must be scrapped! I'm really pissed! Car is running
fine now, but is setting a code for the front bank cat, and won't pass
inspection next month....arghh.
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Posted by Tim Wescott on August 6, 2008, 12:20 am
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On Tue, 05 Aug 2008 19:54:13 -0700, oldjag wrote:
> Some welding content...Got a sort of free 2003 V6 Ford Escape a few
> months ago. Front brakes were shot and I needed a 20 tons on the press
> to remove one of the front rotors from the hub...major rust between the
> OD of the hub and the ID of the rotor hat. Bearings in hubs were shot
> anyway, so replaced them also. Car has three catalytic converters. It
> appears the underbody cat was replaced at some point with aftermarket
> part that sort of fit...probably melted due to a failed coil
> pack...Major exhaust leak on the rear bank manifold cat...can was
> cracked in two places. Had to pull intake manifold, wiring harness,
> alternator, under pan, etc. etc to remove. The substrate looked fine, so
> I TIG welded up the can with some Inconel wire and reinstalled. Before
> putting back the Y pipe, I put a borescope up the outlet of the front
> manifold cat..and guess what... the substrate in the front manifold cat
> is totally gone. It seems that there are no aftermarket front manifold
> cats made for this car, so I may have to shell out 500+ bucks to the
> Ford stealer. Just out of the 80K mile emission warranty too. Local
> junkyards, (not in CA by the way), tell me they are not allowed by law
> to sell perfectly good used units....they must be scrapped! I'm really
> pissed! Car is running fine now, but is setting a code for the front
> bank cat, and won't pass inspection next month....arghh.
I thought the emissions warranty had to be 10 years, per the feds -- or
is it that many years or 80000 miles?
Every time I follow one of those I wonder if someone's put that
independent rear suspension under a Model A -- it looks like it'd fit
just dandy (and in most states you wouldn't need the cat...).
--
Tim Wescott
Control systems and communications consulting
http://www.wescottdesign.com
Need to learn how to apply control theory in your embedded system?
"Applied Control Theory for Embedded Systems" by Tim Wescott
Elsevier/Newnes, http://www.wescottdesign.com/actfes/actfes.html
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Posted by Steve W. on August 6, 2008, 9:45 am
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oldjag wrote:
> Some welding content...Got a sort of free 2003 V6 Ford Escape a few
> months ago. Front brakes were shot and I needed a 20 tons on the press
> to remove one of the front rotors from the hub...major rust between
> the OD of the hub and the ID of the rotor hat. Bearings in hubs were
> shot anyway, so replaced them also. Car has three catalytic
> converters. It appears the underbody cat was replaced at some point
> with aftermarket part that sort of fit...probably melted due to a
> failed coil pack...Major exhaust leak on the rear bank manifold
> cat...can was cracked in two places. Had to pull intake manifold,
> wiring harness, alternator, under pan, etc. etc to remove. The
> substrate looked fine, so I TIG welded up the can with some Inconel
> wire and reinstalled. Before putting back the Y pipe, I put a
> borescope up the outlet of the front manifold cat..and guess what...
> the substrate in the front manifold cat is totally gone. It seems
> that there are no aftermarket front manifold cats made for this car,
> so I may have to shell out 500+ bucks to the Ford stealer. Just out of
> the 80K mile emission warranty too. Local junkyards, (not in CA by the
> way), tell me they are not allowed by law to sell perfectly good used
> units....they must be scrapped! I'm really pissed! Car is running
> fine now, but is setting a code for the front bank cat, and won't pass
> inspection next month....arghh.
Yep, that is one of the Federal laws regarding emissions. Makes it fun
when you have a vehicle that the aftermarket doesn't support. However
all is not lost. You just need to figure out which other vehicle used
the same type of cat but is supported.
--
Steve W.
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Posted by Leo Lichtman on August 6, 2008, 12:49 pm
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"oldjag" wrote: (clip) Local junkyards, (not in CA by the
> way), tell me they are not allowed by law to sell perfectly good used
> units....they must be scrapped! I'm really pissed! (clip)
^^^^^^^^^^^^^^^^^^^^^
Do you need a license to buy scrap metal? I would offer them a REALLY GOOD
price for a small pile of scrap.
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Posted by Jim Stewart on August 6, 2008, 1:59 pm
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Leo Lichtman wrote:
> "oldjag" wrote: (clip) Local junkyards, (not in CA by the
>> way), tell me they are not allowed by law to sell perfectly good used
>> units....they must be scrapped! I'm really pissed! (clip)
> ^^^^^^^^^^^^^^^^^^^^^
> Do you need a license to buy scrap metal? I would offer them a REALLY GOOD
> price for a small pile of scrap.
That's what this pair was looking for...
http://www.sacbee.com/static/weblogs/crime/archives/cat_catalytic_converter_thefts.html
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> months ago. Front brakes were shot and I needed a 20 tons on the press
> to remove one of the front rotors from the hub...major rust between the
> OD of the hub and the ID of the rotor hat. Bearings in hubs were shot
> anyway, so replaced them also. Car has three catalytic converters. It
> appears the underbody cat was replaced at some point with aftermarket
> part that sort of fit...probably melted due to a failed coil
> pack...Major exhaust leak on the rear bank manifold cat...can was
> cracked in two places. Had to pull intake manifold, wiring harness,
> alternator, under pan, etc. etc to remove. The substrate looked fine, so
> I TIG welded up the can with some Inconel wire and reinstalled. Before
> putting back the Y pipe, I put a borescope up the outlet of the front
> manifold cat..and guess what... the substrate in the front manifold cat
> is totally gone. It seems that there are no aftermarket front manifold
> cats made for this car, so I may have to shell out 500+ bucks to the
> Ford stealer. Just out of the 80K mile emission warranty too. Local
> junkyards, (not in CA by the way), tell me they are not allowed by law
> to sell perfectly good used units....they must be scrapped! I'm really
> pissed! Car is running fine now, but is setting a code for the front
> bank cat, and won't pass inspection next month....arghh.