Wn't wind up
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Senior User
Joined: Jul 2003
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From: WA
Wn't wind up
My '89 f250 with 460, stock wouldn't wind beyond 1900 rpm. Couldn't pull the codes 'cause the eec-iv needs two minutes> 2000 rpm. A bright friend suggested o2 sensor. Just for grins, I fired it up with the o2 sensor out. Ran great, loud, but great. Put the sensor in, same problem. Seems like exhaust restriction ?cat. Am I chasing my tail? Is there a way to test cats before I buy one and find out it is a different problem?
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Joined: Jul 2003
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From: WA
Wn't wind up
Well, I had originally planned to start at the muffler end, it started this BS after cruising a few miles on the freeway. Mufflers are a lot cheaper than cats. The truck hadn't been exeercised very vigorously through the winter and this was to be his first big trip since layup. Got to have him towed (with camper) 83 miles back home. I'm glad my AAA was paid up. Thanks
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From: WA
Wn't wind up
I cut the muffler out, looks like the original, and tried to fire it off, didn't work very well. Looks like the cat is plugged. What is the cheapest way to: a. replace the cat with something adequate for performance. B. Avoid a repeat. The cat looks like it is a M.F. to get out and in. Best price i've gotten to have it done approximately stock is ~$850.
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Joined: Dec 1999
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From: Copley, OH
Wn't wind up
$850 is WAY high. Are you using a Ford OEM converter? Forget them, you should be able to get a Catco high-flow aftermarket converter installed for less than half of that amount. The Catco converter is approx. $100-150. If they charge more than $150 labor, they should throw in their sister as part of the deal.
Post Fiend
Joined: Nov 2001
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From: Topsfield, MA
Wn't wind up
I got a Catco high-flow cat from summit racing for 80 bucks. You can drill a small hole in the tailpipe on either side of the cat. Start the truck and have someone rev the engine a little while you put your hand next to the holes. See if the air pressure coming out of the holes is equal. Then take it to a muffler shop and have them weld up the holes, take 2 seconds.
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Joined: Dec 1999
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From: Copley, OH
Wn't wind up
Actually, I was a bit low on the price. The converter you need isCatco #9900 available from Summit as CTO-9900 for $172.39. Direct fit for 87-95 E/Fseries with 7.5L
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From: WA
Wn't wind up
For some reason, these damn things intimidate me. To review, I need a 9900 cat, what about the air pipes? I can weld fairly well. The air pipes look like they're stainless, that is a problem. Do I need to disconnect them at the clamps up toward the exhaust manifold, or just cut the old ones, poke holes (how deep?) and weld it all together. Is the 9900 big enough for this big ******* to breathe? The output side of the current unit, which I assume is stock, is a single 2 1/2 inch going toward the muffler, which was actually included in the $850. The muffler doesn't intimidate me. For the cat alone, stock aftermarket replacement ran ~$400 in parts, 600 installed. The muffler is shot, (see that I mentioned CUTTING it out of the system, cause it was all full of holes). I just don't want to be laying out the dough again in 2000 miles cause I didn't do it right the first time. As you know, welding under a truck is painful.Thanks
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From: WA
Wn't wind up
The 9900 mentioned earlier doesn't have any air pipes already on it, according to the picture. Unbolting, rebolting, putting on hangers ...doesn't bother me. The air pipes are welded to this one. Do I saw off the airpipes at the cat? Is there a source to get sleeves to connect them back? Like I said, never having done one of these, I don't know what I'm in for and I hate surprises "how do I attach this thing, it isn't the same as that one" under the truck.
Post Fiend
Joined: Nov 2001
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From: Neenah, Wisconsin
Wn't wind up
well it comes with stuff to hook up the air pipes to the direct fit. It comes with a high temp plastic piece which i melted. I machined my own billet aluminum one. haven't had a problem since.