The truck is a '96 2.3L Ranger w/ 162K. I recently noticed that the Cat is loose where it meets the exhaust manifold. There is a leak at this point and about 1/8th inch of play (twist). Being that everything is stock from the factory you can imagine the rust build up on the bolts (or is it studs?). Will replacing those bolts be the only thing needed? I have had the codes pulled on it recently when the CEL came on and Autozone said it was an O2 sensor so I am assuming the cat it self is good. There is plenty of pressure out the fairly new muffler. Should I replace the cat since I will most likely need to replace the bolts holding the cat?

As far as O2 sensors, any suggestions? I am not 100% sure on what to get. The mention of multiwire sensors is where I get lost.


I've already started with the PB soakings for those cat/manifold bolts. Not looking forward to it but...

Thanks for any info
Carlos











I had codes pulled at Autozone that came back with a bad O2 sensor.

 

Hi Carlos, I just had the same thing happen to my manifold to cat connection on my 4.6L F150. I live in Buffalo where they use salt in the winter. Getting any kind of exhaust bolt out here is just a pipe dream. I just cut and/or grind the offending bolt off at the manifold,then drill a hole through the manifold where the ground off bolt used to be. Then just drop a bolt down through the hole and run a lock nut and washer up under your clamp. I would not bother trying to drill and tap a hole when you really don't have too. I was able to buy a 15 inch long, 3/8 dia. drill bit for $15 at the local Home Depot. ( there was not enough room on my truck to get a straight shot through the manifold without the long bit.)A 2 piece clamp is also available for under $10 dollars if you have to go for both bolts. ( Just cut the old one right off the cat pipe)My cat does not know the difference between a bolt going into a threaded hole in the manifold and bolt going right through the manifold. It's just happy to be tight!
I would fix the exhaust leak first,then clear the trouble code. If it comes back on ,then replace the sensor. With 162K you will brobably see a good increase in MPG also. I saw my old Ranger (2.3L) jump from about 19 mpg up to 22 mpg when I replaced the sensor at 75K. If your cat isn't broke,why fix it ?
Good luck, Dave P.

 

GuitarDave,

Just wondering what you used to cut/grind the bolts. Its pretty tight with the cat in place, at least on the 2.3L Ranger. I could easily reach the bolts if I cut the cat first but since I am gonna be using the same cat obviously I won't cut it.

I'd rather buy a tool than pay a shop to replace those bolts. Not sure a shop would even want to bother with it.

thanks in advance
Carlos

 

Hi Carlos, One of my bolts was already rusted off,so I only had to cut one.
I used a disk grinder attachment on a Roto-Zip tool. In a pinch I suppose a hacksaw blade with half of it taped up for a handle would do it. A few seconds with a cutting torch would be fine also. Bernzomatic makes a torch that uses one cylinder of propane or mapp gas and one cylinder of oxygen together to produce a very light weight and portable torch for $50. It's becoming one of my favorite tools for under the car. I mostly use it to heat up a nut or bolt (or my 4 darn oxygen sensors) very quickly. It does the job where the regular propane torch won't. This one will weld and cut. It only took a few minutes with the instruction manual to get the right flame for the job. The aftermarket clamp for the cat cost about $10. Good luck. David