Is that what you think? Yes, environmentalism is part of the reason. However, it is only one small part of the reason, the rest is safety to the operator, and other on the road in the form of keeping the noxious chemicals produced in an engine under control. This includes carbon monoxide which is toxic even at low levels, and can have a cummulative toxicity, meaning that it takes a long time for your body to get rid of it, so multiple exposures can gradually cause it to build up. NOX is bad stuff too, burns the eyes, and mucous membranes, can trigger asthma attacks in some people, aggravates allergies, and is the primary reagent that forms visible smog in large cities. The various other hydrocarbons can do the same things, plus some of the hydrocarbons produced in combustion are carcinogenic. The converters are designed to clean the air for people, not the environment. The catalysts effect on the environment is ignorable.

The reason ford has two cats per bank is because having a single larger cat would cause the same sort of problems both Chevy and Dodge have been struggling with for years. The catalyst which is ceramic expands at a different rate than the steel casing. The catalyst is wrapped in a fiber packing which protects it, and keeps it securely held in place. In a small catalyst, this packing does its job well. In larger converters, the difference in the expansion rate causes the packing to loosen allowing the catalyst to move within the packing. After repeated heating and cooling cycles, the packing fails, allowing the catalyst to rattle apart. Even on new chev trucks, this is a very common problem, while on the half ton Ford trucks, this problem is very rare. It is still common on the F-250 and 350 models that use the large torpedo style cat.

The two cats on each bank in the F series can really be though of as a singular unit. They are designed to operate with each other and function together. If you remove some of them, you interfere with the way they are designed to work. All the cats are also technically three way catalysts. In older vehicles some truck would use a pre catalyst that was designed to reduce NOX, while the main cat addressed HC and CO. You could replace those types of units with a single three way cat so long as all the EPA requirements were met. This was because the three way catalyst functioned the same as the two separate original cats. However, on a newer vehicle, all the cats are three way cats, and the vehicle is designed to operate with them in place. No provisions have been made from a legal perspective to allow that kind of modification.

The EPA does not strictly enforce this policy, and they leave the implementation up to the individual states, which in turn often leave that up to the county. If your local smog laws allow your to replace the two cats with a single cat, then there is really nothing stopping you from doing so. And you will gain some sound from doing so. However, do not expect to achieve a satisfactory result from the factory cats by doing so.

My advice on the subject is if you are going to replace the two cats with a single high low, to use a cat such as this. The larger body allows more flow and sound, and causes the tone to be deeper. They will be able to keep your CEL off and pass smog requirements, so long as your local smog laws allow the use of such cats.
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They look good....do they work as good or better than magnaflow's?? Just curious, I have set of Magnflow highflow cat which i intend on installing when I get a chance to do my LT headers...the Ford oem's will not fit because of the extended length of the tubes.

Do you deliver to Canada?.... because I know of a few guys who would buy some of you if the shipping charges aren't too high.

 

Our units are equal to Magnaflows in terms of airflow and sound, and better in terms of efficiency and longevity.

Yes we do ship to Canada, just check the shipping to Canada option on the logout screen. This makes the necessary shipping adjustments. I'm not sure how are shipping charges stack up against anyone else, haven't done a real comparison, our system just makes the adjustments based on past experience with the export fees.