in a quest for additional horsepower I am considering removing the catalytic convertors... has anybody done this? I am planning on following that with a diablo chip... What do i need to consider? (other than the fact that the epa may want to talk.)

 

Welcome to FTE Bill!

I would not recommend removing cats altogether. There are too many sesnors and different things that can be caused by doing that. What I do recommend is removing the 4 OEM cats and replacing them with a hi flow Catco cat. The restriction of the OEM cats is astonishing. The Catco helps out tremendously (along with 3" pipe all the way back)....

Removing the cats altogether can create more headaches than its actually worth. Unless you are building your X to do nothing but run at the track, I would go the other route....

 

I like that idea (high perf cats) better. It is a 97 xlt with the 5.0. It appears to have 4 cats, what can i replace it with? Can i get one dual? what are the best performing aftermarket cats?

 

Catco Dual Catalytic Converter

Here is a pic:



This is the cat I recommend, and am actually running. If you want a good sound, plus the performance, I would have all 4 cats cut off and replaced by this one from Catco. Then cut off the OEM muffler and replace it with a FLowmaster 50 series. Use 3" pipe from the manifolds back. You will love it!

 

Also, you can true dual an Explorer, but the only safe way to do it is to remove the spare tire. This gives you the extra room for the pipe...

 

you can run 3" to the stock manifolds?

 

The manifold is only a 2" I think. You raise it from there....

 

Hey Cobra, does the stock exhaust manifold cause much restriction, cause there aren't any headers avaliable anymore. If you run that cat and stock headers with aftermarket muffler, does it really increase the performance that much? How about a two into one muffler with a 3" outlet for those who don't want to loose the spare tire?

 

i would prefer to keep my spare also, and I am looking for the easiest and cheapest horsepower. the current arrandgement is 2" from the manifolds (these manifold appear to be tubing on a steel plate... no cast iron here) into back to back cats and then both banks into one muffler with a single output into a resonator and out.

I also cannot find aftermarket exhaust (looking for a cheap replacement as I appears I have an exhaust leak in one of the manifolds...)

I cannot find a description of the catco cat at summit, just that picture...

What was the approximate cost of the whole job, cobra?

P.S. thanks a lot for your time!

 

I have not removed my spare yet either. I will be now that the X is not a daily driver. But right now, I am running 3" pipe from the headers all the way back. I have the 2-in-2-out Catco above, and a 2-in-1-out Flowmaster 50 series. Then just a 3" pipe out the right side. It helped out tremendously.

I wish I could find a picture of a set of stock manifolds so you could see how restricted they really are. The stock manifolds are double tubed. You cannot even get your finger in any of the ports on the manifolds, and in some places, a pencil would not fit.

I had a local shop do mine for me. They cut the pipe from the manifolds back, and replaced everything for $350. That included all the pipe, the Catco, and the Flowmaster.

If you are wanting to keep the spare (and I don't blame you), this is the only way I would recommend going. Some people like using Magnaflow or some other muffler - I've really never used anything but Flowmaster - so I can't say on those. They seem like great parts also, so it really shouldn't matter...

On the 4.0's, I would only use 2.25" or 2.5" pipe. The 3" on the 4.0's is too much.



on edit: Bill - Look at the picture of the Catco above. Right above the picture is a link to the cat on Summit.

 

thanks cobra, found the link to the cat.

you replaced the manifolds? where did you find headers?
(or do you have a 4.o?)

 

I have a 5.0, but I bought my headers a long time ago. Ford Motorsport made headers a few years ago - then stopped production on them. I was lucky enough to get a set before then....

 

ah-ha! autopartsauthority.com has headres for the 97 5.0. they also claim that you can go to the ford dealer with the part number (M9430E52) and special order the headers... I am not sure about the price :-o

Accessory Part Detail

Current Vehicle: 1997 FORD EXPLORER
Generic Name(s): HEADERS

Vendor HOOKER (H26)
Part # 6000
» Other vehicles this part fits

Description SWAP HDR 260-302 FRD BLCK
BLOCK HUGGER HEADERS, 255-302W, 1 5/8" TUBE OD, 2 1/2" COLLECTOR OD, PAINTED BLACK, SAME AS PORT
Retail $237.51
Availability IN STOCK

thanks for all your help cobra!

 

I hate to be the bearer of bad news, but they won't have them. The Hooker headers will not fit because of the tight psace in the engine compartment. And the Ford part number is not available anymore.

There are many companies that show they have headers for Explorers, but they have the regular headers for a 302. They are made for Mustangs or F150's, and will not fit in the compartment of the Explorer. The firewall and frame gets in the way on the 302's in the Explorers. Flowtech also shows a set (they are made by Holley), but they are regular headers for Mustangs, and will not clear the firewall on the passenger side of an Explorer.

I know many people that have tried to use them, but no one has been able to get the pipes to bend right to hook them up. There are a few peopl trying to make custom sets, but I don't know of any of them finishing a set yet (that will be mass-produced).

 

waaaahhhh , back to the drawing board...