Ok guys. The exhaust leak on the new truck is being caused by 3 holes in the factory Y pipe. On both the left and right side where the pipe bolts to the manifolds there are small cracks or it is starting to separate. On one of the cats there is also a small hole that I can patch fairly easy however the cracks near the manifolds might not be possible.

I am dusting off the old miller and going to work on it Saturday but what options do I have if this fails. No muffler shop I can find in NY will even attempt the repairs on the Y pipe since the cats are part of if. Personally I just wanted to make a catless Y pipe and call it a day.

Any advice is welcome guys I really don't want to spend $700 on a factory replacement.

 

You have little choice but to replace them because you need emissions inspection.
Without OX sensors you won't pass.
$700+ is for after market cats not OEM.
If you feel $700 is a high price check out the OEM cost then go have a coffee to recover from price shock..
Good luck.

 

Yeah well that's a lot for a truck that I purchased for $900 bucks. That might have 2 or 3 years left before the cancer calls her home.

I don't understand why this truck some how needed 4 cats on it. I wouldn't mind paying 300 or 400 for a custom y pipe with like two magnaflow cats between the manifolds and rear 02s but no one is willing to do it.

 

I am wondering if I could find some one to make a custom Y pipe in one of three configurations.

#1 Use two single magnaflow convertors running one right after each manifold and welding in bungs right after for the down stream O2 sensors. Using 2.25 or 2.5 piping.

#2 Use a single convertor after the Y pipe and extend the rear 02 sensors to run behind it or invest in sims. The only issue I for see with extending the wires is I don't know if the convertor would get hot enough to function properly.

No question that both of these set ups would flow better and still help to protect the environment to at least some degree.

#3 is saying hell with it and just going to a shady shop and getting rid of every thing all together. I don't really like this option because I am not a fan of acid rain however $800-$900 bucks for just a Y pipe is insane IMOP.

 

It is against federal law is why they will not risk a big fine for a little job.
A yard will not sell you a used part for the same reason.
IMO you got the truck for less than partout price for the same reasons the last owner did not want to invest in repairs.
In your case $900 is not a bargain so the last owner came out on top.
Sell it to some one else and learn from it..
Good luck.

 

LOL your joking right.

How many mustangs, lightnings, vettes, and so on are running "high flow cats". Or full aftermarket exhaust systems. Lots

Second why would I try to screw some one over on purpose. Worst case scenario it becomes a farm truck. But I am not ready to throw in the rag just yet.

And finally there is nothing to learn from this except that's one expensive Y pipe. For the money I have in the truck I can get around the emissions if I need to but I am trying to stay legit. I can probably find a stock y pipe out of wrecked truck for less then 150 bucks if need be.

Lots of options out there just looking for advice.

 

I gave you the reality of it 'from your position' as you posted it.
If you came hear to argue the response and know what your options are then do one of them.
I did not just come out from under a rock last week on those options and no I'm not kidding either.

.
Have a good day.

 

I understand your frustration BUT...well... bluegrass is prolly right on target...basically It isn't going to get fixed for $150 bucks. He just cut through the chase and gave you a honest straight forward answer.

aftermarket exhaust prolly will work for you too...but those aftermarket exhaust systems come with a price $$...cheaper ones with long tube headers kits & cross over & Y pipe are down to $500-600 not counting installation and or maybe shipping. More perhaps durable kits are closer to $1600. Folks with vettes and mustangs are more willing to invest those funds because they will see a return on the investment, maybe not all of it but a portion of it. You, on the other hand, have a truck and in all likelyhood won't see the return on investment for the repair outside the fact that it is fixed correctly and IF you decide to sell it, you have the peice of mind that comes from "it has been done right".

I do admire that you are not willing to pass a problem vehicle down the road to some other unsuspecting soul

Most likely... the only way you might get this to stay road-able is the off chance you can find a complete truck that has been wrecked, or blown engine or roasted tranny for extra cheep before the scrap yards get it. that has good parts that you looking for. Then rob parts from one to get the other up and running and do most of the work yourself. You'll probably going to need the title of the donor that you get, ( depending on your state & local laws), so that when you get this, or which ever turns out the better fix, & back in shape you can sell the remaining carcass to the salvage yards...or piece it out yourself. BUT then you have your dollars tied up for a extended period of time. Its a not really a winning situation. as you are well aware of.

 

ebay
Re Certified Catalytic Converter Ford F150 Pickup 1152779 00 01 02 03 Assy | eBay

 

Easy killer, I do respect and thank you for your opinion however I am also not exactly new at this. To the 4.2 ford yes. I have not owned one before. But I do have 13 years of experience so I am not exactly a noob.

 

Can you weld new ends/flares on in front of the light off cats?
We do this quite often in heavy truck/equipment

 

U drill tiny holes at the ends of the cracks and weld them with Mig. It can be done by any muffler shop that is handy. Wire brush and sander on hand grinder will fix it for now. Cutting out the damage and welding in is also an option at the small shop along with bending and making to fit. All for several hundred easy. If U got good metal it will weld. Some surface rust is removable or cut away. Sometimes 2 or 3 feet of pipe is all U need and a good fabricator can make new and angle them together with Mig. He can even Cat-Back 2 pipes for U. Welding and arching a metal rod welding it into place, may be all U need.