My catalytic converter closes to the engine on the driver side has a clicking noise after it warms up. I'm guessing something inside has come apart and it's time to replace them. Anyone else had this happen to their catalytic converter?
Just wanted some imput before I replace them. Thanks

 

How many miles do you have on them?

 

A clicking noise? Sounds to me more like the heat shield. A loose catalyst should make a sound all the time, not just when it warms up. However, the converters closest to the engine are the ones that most frequently fail. When were the O2 sensors last replaced, most catalyst failures are directly related to O2 sensor failure.

 

I'm curious about failure rate on catalytic converters as well. I have a '99 4.6 with 114k. I've had it for about 9k miles, 5 years, I don't drive it much. When I do it's usually short trips, 15-30 miles max.

I've been experiencing a loss in performance, and a change in "sound" to the truck. It's sluggish under load. A friend of mine, a former Ford mechanic, told me what I describe is the gradual demise of the catalytic converter, and gave me the procedure to check it: vacuum gauge on the intake vacuum, crack throttle, monitor vacuum. Haynes manual confirms the process.

I'll be checking it over the next day or two once I pickup a vacuum gauge. Knocking the cat/con with a rubber mallet didn't expose any rattling sounds, but that doesn't mean it's not clogged. I just hope it hasn't hosed my Magnaflow in the process, if it's in fact on the way out.

O2 sensors eh? I've read here about that, seems two schools of thought. No codes, don't replace. Others seem to feel 100k service life on at least the pre-cat sensor. I'm sure neither of mine have been replaced yet.

 

My cats have 180,000 miles on them. The O2 sensors are new, all four of them. The heat shield is ok. I was just wondering if there is anything inside the cats that would come loose. I placed a floor jack under the cat to pry against it when the truck was running and it changed the sound. With that many miles on them I should just replace them anyways. The engine is new and has really good power so I don't think they are plugged but maybe that's because I replace my 4.6 with a 5.4 so I'm going to have more power anyways. Who know maybe I could gain a little more HP by changine both my cats?

 

Turns out my cat is fine. The vacuum test was normal. I'll be replacing my pre-cat O2 sensor along with cleaning the MAF and throttle body.

 

Hello, Im new to this forum. Hope to stay long.

 

Hello There, I am planning to buy a Magnaflow Catalytic Converter so I tried it here. Any suggestions?

 

The inside of your cat can deteriorate and break up.Sometimes they even clog up usually on a higher mileage vehicle,resulting in poor performance and loss of HP.

We carry universal ones that might work for you.

 

I disagree. Yes things can happen to the cats, but it has nothing to do with mileage. The cats deteriorate when something goes wrong with the vehicle, such as a misfire, incomplete combustion, rich condition, lean condition, overheating, blown head gasket, etc. On vehicles that are running correctly, the converter will outlast the 20 year vehicle chassis life, and the 500,000 mile engine life. By those terms, your vehicle isn't even high mileage, though it does have enough miles for something to have gone wrong.

I know you are a new user Kevin, the original post was resolved as far as whether the cats were plugged, but lets continue this thread to help you out. Why are you looking to replace your cats? What it your maintenance history like. How many miles, what engine.

Sight unseen, not knowing your history, let me just answer what I can. Most aftermarket converters, even "high flow" ones use 400 cpi ceramic catalyst. This is the same cell density that Ford uses. Replacing your original 400 cpi cats, with aftermarket 400 cpi ceramic cats results in equal or less power versus stock. The new ones can result in less power because often they are smaller than the original cats. Magnaflow is no exception. They make a 400 cpi ceramic in their standard product. Putting a Magnaflow on your vehicle will not produce more power, so from that standpoint it is just a waste of money.

Before you replace your catalytic converter, you need to identify why your original failed and correct the problem. Ford has exceptionally low converter failure rates. This is especially true of the F series. I would estimate that about 80% of failed cats on F series are the result of deteriorating O2 sensors, or they at least play a role. As the sensors deteriorate, the output voltage decreases. This is interpreted by the computer as a lean condition. The computer adds more fuel, which will have the effect of increasing the sensor voltage. But this new condition would be slightly richer than it should be. This starts a cycle, where additional deposits on the sensor element cause it to further deteriorate. The computer does not have the means of telling the difference between a real lean condition and a deteriorating sensor. For this reason the manufacturer recommend replacing the O2 sensors often enough that this can be avoided. The interval they recommend is usually around 80,000 miles, about the same interval as a double platinum plug. The upstream O2 sensors are involved in the fuel management, so they are the ones that need to be focused on. The downstream sensors are just passive observers of catalyst function, and so long as the vehicle is properly tuned, they are not directly exposed to contamination, so they do not need to be replaced unless they fail. I would recommend removing them and inspecting them when the front sensors are replaced, and when reinstalling them use a little sensor safe anti-seize.

While it is common for some converter to break apart, this is rare on Fords. Dodge and Chevy both have had a lot of failure solver the years due to poor designs, but Ford's four converter design currently used overcomes many of the problems. The Ford system typically consist of a small pre converter, and a larger rear converter. This design overcomes the thermal distortion that breaks the larger single cats used by Chevy and Dodge. Ford did use the "torpedo" style converter, which did often fail, but many cases of that were due to defective thermostats, and this does not happen very often on 1997 and newer vehicles that have been well maintained. Ford used a batter packing material starting in 1996, which further reduced failures.

If you are looking to replace the converters for a performance gain, we have to real high flow converter. We have 300 cpi ceramics, allowing you to use larger oval body converters for the best performance and sound. we do also carry 200 cpi spun metallic, though i don't recommend those as much on trucks. Our website is currently under construction, but you can PM me if that interest you.

 

I guess what I meant was that the more miles you put on a vehicle, the more likely it is for something to go wrong to clog the converter.

I've had converters go bad before.If it's clogged or broken up inside,I'd replace it.