Is that a big deal? When you take the cross member off, does the transmission move?

Ok, so now I'm looking at replacing both cats. Geesh. Should I be doing anthing else while I'm at it? The Exhuast manifolds don't look pretty. In fact the passenger side seems pitted or melted around the pipe connection for the cat. Driver side is much better.

Even though my pipes and muffler seems to be in really good shape, even for being 130k miles old and multiple WI winters I'm thinking "while I'm at it" now might be a good time to do a exhaust too. I've been surfing and getting some ideas. I'm wanting to do anything that improves milage (#1) and makes the truck sound (#2) like a truck but not super loud.

 

I would pull the crossmember. It will just be in the way otherwise. Many exhaust shops end up cutting the new converters to get them in simply because they refuse to remove the crossmember.

 

The pipes on that will be good for a long time. The stock pipe is a type of stainless, and is good for 15 to 20 years in many cases. No point in replacing it unless you really want to change the pipe size.

 

It's not so much I want to change the pipes. More on just the muffler for a better performance and sound. I've looked into those WickedFlow mufflers you have suggested. However I have limited skills and it would mean cutting the pipe and slipping it in there. But as long as you guys keep answering my questions I think I'll be ok.

So do I just bolt off the crossmember? Do I have to support the Tran?

 

Yes.

Also, I don't think installing an aftermarket exhaust will increase mileage enough to offset the cost of buying it.

 

I didn't get much input on the exhaust manifolds so I thought I'd include two pictures.

Passenger side:


Driver side:


Is it just me, or are these two different type of manifolds? Looking carefully at the passenger side one can you see how it looks melted or deformed around the bolt? Maybe it's not big deal and looks perfectly normal?

Do I replace the bolt/stud before putting on a new cat? Does this deformation warrant a new mainfold or some nice headers? My thoughts are, these seem to fail at some point and will only get harder to change overtime. I have some time now to work on it now.

 

If you really want to get more performance and better fuel economy, install a set of headers. Shorty ones are fine and will bolt right up to your cats.

Looks like someone tightened down the exhaust to manifold joint too tight and crimped the flange. I would not worry about it if you want to just bolt up your cats.

 

Shopping time. Need to get some parts.

Looking at theses for the Cats:

Eastern Cats ($500 both)
EASTERN MANUFACTURING Catalytic Convt,30477 - wUnderCarParts.com
EASTERN MANUFACTURING Catalytic Convt,30476 - wUnderCarParts.com

OR (not really sure if I can justify the price difference for these)
BearRiver Converters ($1200 for both)
Item Details

JBA Headers 1679S ($410)
http://www.summitracing.com/parts/JBA-1679S/

Bosch O2 Sensors: ($200) Could be more, depending on if I've picked out the right one for the before cat sensor.
PartsTrain.com - Hard to Find Auto Parts and Truck Parts -

PartsTrain.com - Hard to Find Auto Parts and Truck Parts -


And perhaps WickedFlow MAX 18SC250 ($90)
Item Details




+ shipping + misc parts + some tools....

Is this a good setup? Anything else I should be thinking about since I'm going to headers and cats to exhaust? The headers are pretty basic non painted ss.

Don't be afraid to tell me something I have picked out is junk. Or let me know if there's a better vendor I should look at.

Thanks.

 

You might save some money on the o2 sensors at Discount Auto Parts Online - Mercedes Parts, BMW Parts, Volvo Parts, Volkswagen Parts - PartsGeek.com New Auto Body Parts
Headers - the JBA are good but you can save some money if you want and get something a little cheaper off ebay or other sights if you want.
Cats - not sure. Just do a shopping.google.com search and have it sort by price. I would try and find some high flow cats if you can.
Muffler - depends on if you want loud or not.

 

My advise on the JBAs, other stuff may be cheaper, but find something cheaper that fits correctly, has proven performance gains, doesn't leak, and is made of stainless steel. I personally would go for the cheapest JBAs, but I wouldn't put much effort into looking at the cheaper brands unless settling with a non-stainless header was acceptable. Considering how your manifolds have rusted, I don't think a cheaper header is a good route.

No body makes high flow cats for this application. If you want to do high flow cats, you will have to have them welded in.

 

Don't want to open a can of worms, what are the benefits of a high flow cat? I have a person in the family that might be able to do some welding for me. Is it a noticeable difference? Would it be worth it?

 

I think it would be. With the headers, high flow cats, new high flow muffler your going to see at least a 2 mpg increase in fuel economy.
While your changing, why not get the best fuel economy you can.

I know magnaflow makes some. I am sure others do as well.

 

I'd have to have more proof the $1200 converters were better when the factory one's are probably near that price. Look at the pictures from both companies they are the same. Same poor quality, undersized, non-mandrel bent pipes unlike the oem's. There will probably be zero performance gain from headers or mufflers after these restrictive units are installed.

The statement in 'Red', to me, is somewhat misleading. If O2's cause Po420 code I'd be changing them out before purchasing new converters not after. In your case though your cats are broken.

Have you tried the junk yards or checked the oem prices?

Have you phoned a muffler shop to see how they would do the job with a price quote? Maybe they leave the oem's in, cut the cats out, tack new one's in and then weld either with the pipes installed or removed from the vehicle? I don't know, just a thought.

 

You can get high flow magnaflow cats that are weld in for $89.00 each from JC Whitney.

Universal Catalytic Converters for 49 States - JCWhitney

States that it is made of stainless steel. Magnaflow brand. High Flow. Weld in. Designed for 2002 F150.

Keep searching around. shopping.google.com will help you find stuff cheap.

 

You'd be surprised I think. I'd challenge you to find OEM Cats for my truck for under $1200 a piece. (those above are $600 a piece) I had a quote before I started to do this myself, and they would have got a universal cat and welded it in. But now that I have it apart I know both cats are junk not just the one he was going to do. My thought process was - I'm not afraid to do the work myself, and maybe with the money saved I could do a few extra things (like headers and a better sounding muffler), get a direct fit. I didn't want to get into welding and stuff. But maybe I can see if I can have a shop just do that for me. my stock pipes are in pretty decent condition.

Checking a junk yard is not a bad idea. I may have to do that in the next couple of days. That should keep the cost down, but I'm not sure if it'll do much as far as maximizing performance for my project. Maybe checking with a shop or two if they will retrofit performace cats to exsisting OEM cat pipes. I'm worried the fit won't be that good with this route.

Got the exhaust manifolds off today. I had about 3 screws that broke off at the manifold top and about 3 others that the nut came off and the screw was left in tack. Got those soaking, also had trouble disconnecting the egr connection. That too is soading in penetrating oil for a day or two.

I really appreciate all the help so far!