Start up my Escape the other day (2004 V6) and right off the bat it's running terribly with no power, surging idle. At times I had it floored and it was going 20 other times 60 but never smooth. But I had to get to work for an important appt. After that I start heading to my mechanic 10 miles away. About 1/2 way there there is the loud sound of air rushing in the engine compartment. Turns out one of the catalytic converter was completely clogged and the backpressure developed a crack which turned into a big whole in the EGR. After 70 miles of driving my check engine light is back on. What could cause the original cat to fail with only 49,000 on the odemoter and what could be cause an error code now showing a problem with the new cat?

 

In case I wasn't clear I had the EGR and catalytic converter replaced and now after 70 miles the check engine is back on showing same code (vehicle is running fine though)

 

Muntiple cats. They all need replacing.

 

IIRC oem cats are guaranteed at least 50,000 miles under the Federal regs. Check your owner's manual. Codes checked? Autopsy on the cat, death due to high heat or just fall apart? Check it out, don't pay for what should be covered....

 

From https://www.fleet.ford.com/maintenan...ls/default.asp

QUICK REFERENCE: EMISSIONS WARRANTY COVERAGE
This chart shows your warranty coverage under two emissions warranties
that Ford Motor Company provides, in compliance with Federal requirements.
The warranties are:
• Emissions Defect Warranty
• Emissions Performance Warranty
For full details on emissions control coverage, see:
➡ Emissions Defect Warranty (page 12)
➡ Emissions Performance Warranty (pages 12-13)
➡ What is Covered? (pages 13-14)
➡ What is Not Covered? (page 14)

pg11
EMISSIONS DEFECT WARRANTY COVERAGE
Under the Emissions Defect Warranty, Ford Motor Company provides
coverage for 3 years or 36,000 miles (whichever occurs first). This is an
extension of the federal requirement that calls for coverage of
2 years/24,000 miles (whichever occurs first) for passenger car and light
duty trucks. Certified heavy duty engines (vehicles with a GVWR over
8,500 pounds) are provided coverage for 5 years or 50,000 miles (whichever
occurs first).
During this coverage period, Ford Motor Company warrants that:
• your vehicle or engine is designed, built, and equipped to meet - at
the time it is sold - the emissions regulations of the U.S. EPA.
• your vehicle or engine is free from defects in factory-supplied materials
or workmanship that could prevent it from conforming with applicable
EPA regulations.
• you will not be charged for repair, replacement, or adjustment of defective
emissions-related parts listed under What is Covered? on
pages 13-14.
Under the Emissions Defect Warranty for passenger cars and light duty
trucks (vehicles with a GVWR of 8,500 pounds or less), Ford Motor Company
also provides coverage, including labor and diagnosis, for 8 years or
80,000 miles (whichever occurs first) for these emissions parts:
• catalytic converter
• electronic emissions control unit (PCM)
• onboard emissions diagnostic device
• NVG module (Bi-fuel/CNG)
EMISSIONS PERFORMANCE WARRANTY COVERAGE
If your vehicle is registered in a state where the state or local government has
an EPA-approved inspection and maintenance program, you may also be eligible
for Emissions Performance Warranty Coverage for 2 years or 24,000 miles
(whichever occurs first), if you meet the conditions listed below in this section.
Under the Emissions Performance Warranty for passenger cars and light duty
trucks, Ford Motor Company also provides coverage, including labor and diagnosis,
for 8 years or 80,000 miles (whichever occurs first) for the following
emissions parts, if you meet the conditions listed below in this section.
• catalytic converter
• electronic emissions control unit (PCM)
• onboard emissions diagnostic device
• NVG module (Bi-fuel/CNG)
pg12
Under Emissions Performance Warranty Coverage, Ford Motor Company will
repair, replace, or adjust - with no charge for labor, diagnosis, or parts - any
emissions control device or system, if you meet all these conditions:
• You have maintained and operated your vehicle according to the instructions
on proper care in the Owner Guide, the Scheduled Maintenance
Guide, and this booklet.
• Your vehicle fails to conform, during the warranty coverage period of
2 years or 24,000 miles (whichever occurs first), to the applicable national
EPA standards.
• You are subject to a penalty or sanction under local, state, or federal
law because your vehicle has failed to conform to the emissions standards.
(A penalty or sanction can include being denied the right to
use your vehicle.)
• Your vehicle has not been tampered with, misused, or abused.
The Emissions Performance Warranty will not apply to your vehicle if:
• the vehicle is tested at high altitude, but is certified to meet standards
only at sea level.
• the diagnosis shows your vehicle will pass the applicable state or local
government test using test procedures and standards set by the EPA.
Note that the warranty period begins on the Warranty Start Date as
specified on page 2 of this booklet.
WHAT IS COVERED?
These parts are covered by both the Emissions Defect Warranty and the
Emissions Performance Warranty.
List of Parts Covered by Emissions Warranties
• Air Flow Sensor
• Air/Fuel Feedback Control System and Sensors
• Air Induction System
• Altitude Compensation System
• Catalytic Converter
• Cold Start Enrichment System
• Cold Start Fuel Injector (1)
• Controls for Deceleration
• Electronic Ignition System
• Exhaust Pipe (Manifold to Catalyst)
• Electronic Engine Control Sensors and Switches
• Evaporative Emission Control System
• Exhaust Gas Recirculation (EGR) System
• Exhaust Heat Control Valve
• Exhaust Manifold
pg13
• Fuel Filler Cap and Neck Restrictor
• Fuel Injection System
• Fuel Injector Supply Manifold
• Fuel Sensor (1)
• Fuel Tank (non diesel only)
• Fuel Tank Pressure Control Valve (1)
• Idle Air Bypass Valve
• Ignition Coil and/or Control Module
• Intake Manifold
• Intercooler Assembly - Engine Charger
• Malfunction Indicator Lamp (MIL)/On-Board Diagnostic (OBD) System
• PCV System and Oil Filler Cap
• Powertrain Control Module
• Secondary Air Injection System
• Spark Control Components
• Spark Plugs and Ignition Wires
• Synchronizer Assembly
• Throttle Body Assembly (MFI)
• Turbocharger Assembly
• NVG module (Bi-fuel/CNG)
(1) Flex Fuel vehicle only
Important Information About List of Parts
Also covered by the two emissions warranties are all emissions-related
bulbs, hoses, clamps, brackets, tubes, gaskets, seals, belts, connectors,
non diesel fuel lines, and wiring harnesses that are used with components
on the list of parts, above.
Concerning parts that should be replaced on a certain maintenance
schedule: these parts remain under warranty until : (a) the first replacement
time that is specified in your Owner Guide and the Scheduled
Maintenance Guide; or (b) the time or mileage limits of the Federal
Defect and Performance Warranties (whichever occurs first).
Your Ford Motor Company dealer maintains a complete list of parts covered
by emissions warranties. For more details about the specific parts
covered by the Emissions Defect Warranty, contact your dealer.
WHAT IS NOT COVERED?
Ford Motor Company may deny you warranty coverage if your vehicle or
a part has failed because of abuse, neglect, improper maintenance, unapproved
modifications, or any items included in What Is Not Covered?,
pages 7-9.
pg14
NOT COVERED
WHAT IS NOT COVERED?
Damage Caused By:
• accidents, collision or objects striking the vehicle (including driving
through a car wash)
• theft, vandalism, or riot
• fire or explosion
• using contaminated or improper fuel/fluids
• customer-applied chemicals or accidental spills
• driving through water deep enough to cause water to be ingested into
the engine
• misuse of the vehicle, such a driving over curbs, overloading, racing or
using the vehicle as a stationary power source
Damage Caused by Alteration or Modification
The New Vehicle Limited Warranty does not cover any damage caused by:
• alterations or modifications of the vehicle, including the body, chassis, or
components, after the vehicle leaves the control of Ford Motor Company
pg7
• tampering with the vehicle, tampering with the emissions systems or
with the other parts that affect these systems (for example, but not
limited to exhaust and intake systems)
• the installation or use of a non-Ford Motor Company part (other than
a certified emissions part) or any part (Ford or non-Ford) designed
for off-road use only installed after the vehicle leaves the control of
Ford Motor Company, if the non-Ford part fails or causes a Ford part
to fail. Examples include, but are not limited to lift kits, oversized
tires, roll bars, cellular phones, alarm systems, automatic starting systems
and performance-enhancing powertrain components
Damage Caused by Use and/or the Environment
The New Vehicle Limited Warranty does not cover surface rust, deterioration
and damage of paint, trim, upholstery, and other appearance items
that result from use and/or exposure to the elements. You, as the owner,
are responsible for these items. Some examples are:
• dings, dents
• cuts, burns, punctures or tears
• road salt
• tree sap, bird and bee droppings
• windstorm, lightening, hail
• earthquake
• freezing, water or flood
• stone chips, scratches (some examples are on paint and glass)
• windshield stress cracks. However, limited coverage on windshield stress
cracks will be provided for the first 12 months in service, regardless of
miles driven, even though caused by use and/or exposure to the elements.
Maintenance/Wear
The New Vehicle Limited Warranty does not cover: (1) parts and labor
needed to maintain the vehicle; and (2) the replacement of parts due to
normal wear and tear. You, as the owner, are responsible for these items.
See your Scheduled Maintenance Guide. Some examples of maintenance
and normal wear are:
• oil changes
• oils, lubricants, other fluids
• oil/air filters
• tire rotation
• cleaning/polishing
• clutch linings
• Wiper blades
• Wheel alignments and tire
balancing
• Brake pad/lining
Some maintenance and wear items have limited coverage, as follows:
• wiper blade replacements are not
covered beyond 12 months in service,
regardless of miles driven
pg8
• wheel alignments and tire balancing
(unless required by a warranty
repair) are not covered
beyond 12 months or 12,000
miles, whichever occurs first
• Brake pad/lining replacements
are not covered beyond 12
months or 18,000 miles, whichever
occurs first
Tire Wear or Damage
The New Vehicle Limited Warranty does not cover normal wear or wornout
tires. Tires will not be replaced (unless required by a warranty repair)
for wear or damage including:
• tire damage from road hazard such as cuts, snags, bruises, bulges,
puncture, and impact breaks
• tire damage due to under or over inflation, tire chain use, racing, spinning
(as when stuck in snow or mud), improper mounting or dismounting,
or tire repair
• tire vibration or ride harshness and uneven or rapid tire wear. However,
limited coverage for these conditions will be provided for the
first 12 months in service or 12,000 miles, whichever occurs first, even
though caused by maintenance and wear items such as wheel alignment
or tire balancing. This limitation for ride harshness and uneven
or rapid tire wear does not apply to tire replacement on the New Style
F-150 Truck. (Note: the 12 month/12,000 mile, whichever occurs first,
limitation does apply to the F-150 Heritage Truck.)
Other Items or Conditions Not Covered
The New Vehicle Limited Warranty does not cover:
• vehicles that have had the odometer disconnected, altered, or inoperative
for an extended period of time with the result that the actual
mileage cannot be determined
• vehicles that have ever been labeled or branded as dismantled, fire,
flood, junk, rebuilt, reconstructed, or salvaged; this will void
the New Vehicle Limited Warranty
• vehicles that have been determined to be a total loss by an insurance
company; this will void the New Vehicle Limited Warranty
• any Ford or Mercury vehicles (except Excursion modified by a Qualified
Vehicle Modifier using the XLT package with a 6.8L engine and
4:30 axle (XC3) that are converted to limousines. This will void the
New Vehicle Limited Warranty. See additional information about authorized
Excursion modification on page 28
• converted ambulances that are not equipped with the Ford Ambulance
Prep Package, see important information about ambulance conversions
(page 28)
pg9

 

If it's eating CATS, you have a serious problem!!

 

Any idea what could be causing cats to fail though? I have read of quite a few people with escapes having the cats fail within 70,000 miles. Doesn't seem like they were well desogned and the front ones are big bucks. I replaced the egr, o2 sensors, rear cat that failed and the fure filter. After I had the work done I found out about the 8 year, 80,000 mile coverage on catalytic converters but not sure if I can get any reimbursement since I had the work done by my local mechanic and not a ford dealership. I'm going to try going to ford on Monday about my current check engine light but worried because the new replacement catalytic converter is not oem and not sure if they'll use that to deny and warranty. I guess I'll find out on Monday and hope for the best.

 

From what I've read, either the insides fall apart from age or it melts from intense heat. Unburned feul from poor engine combustion enters the CAT and burns there. I've seen one turn cherry red because of this but this was on a older car, pre OBD system.

You'd think a newer vehicle's PCM with O2's monitoring the exhaust gas, it would catch a problem before it destroys a CAT!

 

what was / is the code???? and how are the codes being read??? The interpretation of the code is very important but without the code, you are asking the forum to "guess" at your interpretation. Other than that, issues like "unusual gas mileage conditions" even without a CEL light may indicate problems that need further analysis. Any previous CEL light codes might have been misinterpreted leaving root conditions undiagnosed.

 

Yeah, my 01 front cat (front of car) disintegrated, then clogged the furthest back cat on the v6. We have 115k and way over warranty. Ended up finding a rebuilt one on ebay, replaced the front one and removed the insides off the furthest back one. It now runs like a bat out of hell. I have no idea why they fail, but they just do on these Escapes. We're selling ours.

 

OBDII, get one at your local auto parts store.

 

They are asking the original poster about "the" codes. No actual DTC numbers were ever mentioned.

Lots of times someone will get a O2 code and replace the O2, it's just the messenger.

 

Oh, gotcha. I'll be quiet.

 

2001 Escape 3.0L, 6 Cyl. 115K miles. Three of the ignition coils failed, which dumped gas into the catalytic converter. There was a bang and the EGR valve now had a hole about the size of a dime in the side. The mechanic said he'd never seen anything like it. The front converters cooked and sent all kinds of pieces back into the other converter and plugged it. Replaced the rear converter and it runs OK. I did not have the $2500.00 Ford wanted for the work.

Now a fourth ignition coil is dying. Yeehaw.

 

I still have all 6 original coils and cats in my '02 with 157,000 miles. But for how long?