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Any ideas would be appreciated. Here is the story.
My son borrowed my 1985 f150 300 six engine. 17k miles after overhaul. While he had it the catalytic converter broke up and some of the converter plugged the exhaust. It started blowing oil out the breather cap into the air cleaner and eventually all over the engine compartment. It eventually blew back enough to melt the air tube and the valve on the emissions setup. I cut the converter off and the engine came back to normal for power and everything but I still get a considerable amount of smoke from the tailpipe. I hope I didn't burn any valves. I haven't done any troubleshooting yet been to cold. I was wondering if it might have just blew the oil seals off of the valves.
When a cat gets stopped up, it quits running, there isn't any back pressure thru the engine to cause the it to start smoking, more than likely if its a fresh rebuild. one of the oil rings has gotten turned to the compression ring whereas oil could be seeping past it...or you got a bad rebuild job. I just don't buy the idea about the cat. being stopped up to create back pressure to blow the seals from the valve guides either. You have to be running really rich for the cat to burn up or you are useing leaded fuel. If which case either one or the other will make the engine run like crap....
Smokes mostly when revving it up. I don't see any difference when I remove the breather cap. The cat apparently droped some big chunks which dropped back to the back and plugged it. The cat was only 3 months old. When I removed it there was a big chunk wedged sideways in the exit side.
From what I gather from what you have told us;
The catalytic converter plugged,
your son overheated the crap out of the new motor trying to get to his destination.
This prematurely wore out the pistons, rings and cylinder bores.
Time for a new motor!
Steve G.