$49.95 head pipe catalytic converter replacement on 2001 4.0 - Fixed my P0432 code - Jeep Wrangler Forum
Jeep Wrangler Forum

Go Back   Jeep Wrangler Forum > TJ Jeep Wrangler Forum > TJ General Discussion Forum

Join Wrangler Forum Today


Reply
 
Thread Tools

Please support our sponsors and let them know you heard about them on WranglerForum.com
Old 09-01-2012, 12:41 PM   #1
Jeeper
 
Join Date: Oct 2011
Posts: 17
$49.95 head pipe catalytic converter replacement on 2001 4.0 - Fixed my P0432 code

My 2001 4.0L TJ was throwing out the P0432 code- Catalyst System Low Efficiency Bank 2. Thanks to the incredibly wicked awesome $4.95 Torque Pro OBDII Android app and a wireless bluetooth OBDII code scanner, I discovered that the pre and post O2 sensors were returning basically identical voltages, indicating that the catalytic converter had no effect on the exhaust passing through it.




Since both O2 sensors passed testing, I was confident the problem had to be the catalytic converter. Rather than spend $300+ on a replacement head pipe, I thought I'd risk $49.95 and try to "cut and paste" in a universal cat. I used a "Thunderbolt Universal Catalytic Converter 2" OBD II Compliant..." I found on ebay (the link takes you to the seller's store). It was the shortest one I found and reasonably priced.


To assure that the head pipe would line up with the exhaust header after welding in the new cat, I used a jig. I made two steel plates with holes drilled on 3.5" centers, bolted them to each flange and then joined the plates with a third section. So when I cut out the bad kitty, the flange hasn't moved from it's original position.





The photo below shows the bad cat removed and the flange "floating" in it's original position.





The new and the old converters.





After determining how to align the new converter to the head pipe, I shortened it at each end so that it was about 1/2" longer than the old section I cut out (sorry, no photo.) I then made cuts into the ends with a band saw to create tabs, and bent them inward with pliers to fit the top and bottom diameters of the head pipe. Bending in the tabs reduced the overall length of the new cat, which is why I added the extra 1/2" in length. The result was just enough overlap of old pipe to accommodate the welds.





Top and bottom fit after sliding the new converter into place.





Welded in and ready to install.





The flanges lined up perfectly to the exhaust manifold, the P0432 code didn't return and I passed the emissions test the following day!


When I bought the Jeep in 2011, the P0432 was part of the reason the previous owner was selling it. A dealer had told him that all 3 cats needed to be replaced at a cost of over $2,400.00. It's such a shame.

.

tpeerson is offline   Quote Quick Reply
Old 09-01-2012, 01:06 PM   #2
Jeeper
 
TnDz TJ's Avatar
 
Join Date: Apr 2011
Location: Reno, NV
Posts: 2,925
Images: 220
You are my hero!!! I was hoping and praying someone would try this out. Give a shout back in about 2 weeks of driving and let us know if the CEL and code comes back.

Thanks for the kitty link too!!!

__________________
~Todd~ 2004 X 4.0 5 speed---SOLD
4" Lift, 4.56's, 33" Duratracs on M/T Classics
RR SYE, Tatton CV, MML, BL, TT, Dynomax Exhaust
Hella Lighting: Driving, Fogs and H4 E-Codes
NOPE! ... and NEVER will be...
TnDz TJ is offline   Quote Quick Reply
Old 09-01-2012, 01:28 PM   #3
Knows a couple things...

WF Supporting Member
 
Jerry Bransford's Avatar
 
Join Date: Nov 2005
Location: Escondido, Calif.
Posts: 30,852
Images: 2
That was awesome, please come to San Diego and do the same thing to mine. I could weld the new cat into place but I'm too old and lazy to want to have to pull all that off the engine.
__________________
When you have a choice, buy American.

Jerry Bransford is online now   Quote Quick Reply
Old 09-01-2012, 03:27 PM   #4
Jeeper
 
Join Date: Oct 2011
Posts: 17
Thanks guys!

TnDz TJ
- I did this back in April, a little over 4 months ago... never saw the code again.

Jerry- It really wasn't a big deal dropping the head pipe, and you can't beat the $aving$.
tpeerson is offline   Quote Quick Reply
Old 09-01-2012, 03:37 PM   #5
Jeeper
 
TnDz TJ's Avatar
 
Join Date: Apr 2011
Location: Reno, NV
Posts: 2,925
Images: 220
NICE!!! Thanks again for the info... gonna head this up and replace both while I'm at it.... can't hurt and only for $100.... shoot... can't pass this up.
__________________
~Todd~ 2004 X 4.0 5 speed---SOLD
4" Lift, 4.56's, 33" Duratracs on M/T Classics
RR SYE, Tatton CV, MML, BL, TT, Dynomax Exhaust
Hella Lighting: Driving, Fogs and H4 E-Codes
NOPE! ... and NEVER will be...
TnDz TJ is offline   Quote Quick Reply
Old 09-01-2012, 04:20 PM   #6
Jeeper
 
Join Date: Oct 2011
Posts: 17
Great! Please post your progress.
tpeerson is offline   Quote Quick Reply
Old 09-01-2012, 04:31 PM   #7
Jeeper
 
Join Date: Dec 2011
Location: Hill Country
Posts: 729
That just seems too easy. Nice write up, should be a sticky so I can find it when I have to do mine.
Tdog02 is offline   Quote Quick Reply
Old 09-01-2012, 05:07 PM   #8
Jeeper
 
Join Date: Oct 2011
Posts: 17
Oooh, it would be an honor to be sticky!
tpeerson is offline   Quote Quick Reply
Old 09-01-2012, 07:19 PM   #9
Jeeper
 
TnDz TJ's Avatar
 
Join Date: Apr 2011
Location: Reno, NV
Posts: 2,925
Images: 220
Quote:
Originally Posted by tpeerson View Post
Oooh, it would be an honor to be sticky!
I would say so!!! 4th post? sheesh! LOL!!!
__________________
~Todd~ 2004 X 4.0 5 speed---SOLD
4" Lift, 4.56's, 33" Duratracs on M/T Classics
RR SYE, Tatton CV, MML, BL, TT, Dynomax Exhaust
Hella Lighting: Driving, Fogs and H4 E-Codes
NOPE! ... and NEVER will be...
TnDz TJ is offline   Quote Quick Reply
Old 09-01-2012, 08:40 PM   #10
Jeeper
 
Join Date: Oct 2011
Posts: 17
Quote:
Originally Posted by TnDz TJ View Post
I would say so!!! 4th post? sheesh! LOL!!!
Actually, uhmmm... that was my 4th post you just replied to!
tpeerson is offline   Quote Quick Reply
Old 09-01-2012, 08:55 PM   #11
Jeeper
 
TnDz TJ's Avatar
 
Join Date: Apr 2011
Location: Reno, NV
Posts: 2,925
Images: 220
Quote:
Originally Posted by tpeerson View Post
Actually, uhmmm... that was my 4th post you just replied to!
um yeah... I know.... just trying to keep you going... lol!!! Nice Job!!!
__________________
~Todd~ 2004 X 4.0 5 speed---SOLD
4" Lift, 4.56's, 33" Duratracs on M/T Classics
RR SYE, Tatton CV, MML, BL, TT, Dynomax Exhaust
Hella Lighting: Driving, Fogs and H4 E-Codes
NOPE! ... and NEVER will be...
TnDz TJ is offline   Quote Quick Reply
Old 09-17-2012, 07:55 AM   #12
Jeeper
 
hammmike's Avatar
 
Join Date: Oct 2011
Posts: 32
That is a really neat fix. I had a set replaced on my jeep and paid way to much to have it done. I never even considered something like this.
hammmike is offline   Quote Quick Reply
Old 09-17-2012, 07:55 AM   #13
Jeeper
 
hammmike's Avatar
 
Join Date: Oct 2011
Posts: 32
bump
hammmike is offline   Quote Quick Reply
Old 09-17-2012, 07:56 AM   #14
Jeeper
 
hammmike's Avatar
 
Join Date: Oct 2011
Posts: 32
I need to get in 15 posts so I can post in the classified ads
hammmike is offline   Quote Quick Reply
Old 09-17-2012, 07:57 AM   #15
Jeeper
 
hammmike's Avatar
 
Join Date: Oct 2011
Posts: 32
I still need two more.
hammmike is offline   Quote Quick Reply
Old 09-17-2012, 08:42 AM   #16
Jeeper
 
Mark b's Avatar
 
Join Date: Aug 2012
Posts: 264
Awesome! That is really cool. There is no aftermarket downpipe with cats for the TJ's correct?
__________________
1948 CJ2A | 2004 TJ Rubicon
Mark b is offline   Quote Quick Reply
Old 09-17-2012, 09:32 AM   #17
Supporting Member

WF Supporting Member
 
HarryJeepGuy's Avatar
 
Join Date: Dec 2010
Posts: 3,071
Quote:
Originally Posted by Mark b
Awesome! That is really cool. There is no aftermarket downpipe with cats for the TJ's correct?
Rockauto.com
HarryJeepGuy is online now   Quote Quick Reply
Old 09-17-2012, 09:52 AM   #18
Jeeper
 
frieed's Avatar
 
Join Date: Jan 2012
Location: Utah
Posts: 110
Images: 1
Ingenious solution, but I gotta ask, did you weld it up with stainless filler ?

I hope so, because at the temps those cats run mild steel will rust out pretty fast and you'll get to do it again.
__________________
2012 JKUR, LOD Mid Width Front Bumper
Warn M8000 winch, Modified stock Rubicon sliders
Teraflex 2.5" coil lift, Pull Pal
FJ Cruiser roof mod (painted white)
frieed is offline   Quote Quick Reply
Old 09-17-2012, 03:36 PM   #19
Jeeper
 
TnDz TJ's Avatar
 
Join Date: Apr 2011
Location: Reno, NV
Posts: 2,925
Images: 220
Quote:
Originally Posted by Mark b View Post
Awesome! That is really cool. There is no aftermarket downpipe with cats for the TJ's correct?

X2 on the Rock Auto... cheapest I have found at $300 or so..... but for $100, I will be doing this cat swap within the next month or two.
__________________
~Todd~ 2004 X 4.0 5 speed---SOLD
4" Lift, 4.56's, 33" Duratracs on M/T Classics
RR SYE, Tatton CV, MML, BL, TT, Dynomax Exhaust
Hella Lighting: Driving, Fogs and H4 E-Codes
NOPE! ... and NEVER will be...
TnDz TJ is offline   Quote Quick Reply
Old 09-17-2012, 09:19 PM   #20
Jeeper
 
Join Date: Oct 2011
Posts: 17
Quote:
Originally Posted by frieed View Post
Ingenious solution, but I gotta ask, did you weld it up with stainless filler ?

I hope so, because at the temps those cats run mild steel will rust out pretty fast and you'll get to do it again.

Unfortunately, I didn't become aware of using stainless filler until afterwards. I'll check it next spring and see how it's doing. Thanks for the tip!
tpeerson is offline   Quote Quick Reply
Old 09-17-2012, 09:21 PM   #21
Jeeper
 
Join Date: Oct 2011
Posts: 17
Quote:
Originally Posted by TnDz TJ View Post
X2 on the Rock Auto... cheapest I have found at $300 or so..... but for $100, I will be doing this cat swap within the next month or two.
Yeah, Rock Auto was the lowest price I found. Great place. I've ordered a lot from them. They're often the best price.
tpeerson is offline   Quote Quick Reply
Old 09-17-2012, 09:23 PM   #22
Jeeper
 
Join Date: Oct 2011
Posts: 17
Quote:
Originally Posted by TnDz TJ View Post
X2 on the Rock Auto... cheapest I have found at $300 or so..... but for $100, I will be doing this cat swap within the next month or two.
Just don't cut BOTH cats out at the same time!
tpeerson is offline   Quote Quick Reply
Old 09-17-2012, 09:26 PM   #23
Jeeper
 
TnDz TJ's Avatar
 
Join Date: Apr 2011
Location: Reno, NV
Posts: 2,925
Images: 220
Quote:
Originally Posted by tpeerson View Post
Just don't cut BOTH cats out at the same time!
LMAO!!!! Oh I would kick myself soooo hard.... LOL!!!!

tpeerson,


Do you recall the actual OD of the the exhaust tube? I havent measured mine yet, wondering if it really matters from 2-2.5" due to cutting and reducing inward. thanks!
__________________
~Todd~ 2004 X 4.0 5 speed---SOLD
4" Lift, 4.56's, 33" Duratracs on M/T Classics
RR SYE, Tatton CV, MML, BL, TT, Dynomax Exhaust
Hella Lighting: Driving, Fogs and H4 E-Codes
NOPE! ... and NEVER will be...
TnDz TJ is offline   Quote Quick Reply
Old 09-17-2012, 09:39 PM   #24
Jeeper
 
Join Date: Oct 2011
Posts: 17
Quote:
Originally Posted by TnDz TJ View Post
... Do you recall the actual OD of the the exhaust tube? I havent measured mine yet, wondering if it really matters from 2-2.5" due to cutting and reducing inward. thanks!

I bought a 2 1/4" O.D., but yeah, you end up cutting the pipe off anyway. I'd just buy the one that cost less if there was a price difference.
tpeerson is offline   Quote Quick Reply
Old 09-17-2012, 09:47 PM   #25
Newb
 
Join Date: Sep 2012
Posts: 6
That just seems too easy.
BarryDaviso is offline   Quote Quick Reply
Old 09-17-2012, 10:41 PM   #26
Jeeper
 
TnDz TJ's Avatar
 
Join Date: Apr 2011
Location: Reno, NV
Posts: 2,925
Images: 220
Quote:
Originally Posted by tpeerson View Post
I bought a 2 1/4" O.D., but yeah, you end up cutting the pipe off anyway. I'd just buy the one that cost less if there was a price difference.

Thanks... the only concern that comes up is flow... is there a difference? HMMMMM....
__________________
~Todd~ 2004 X 4.0 5 speed---SOLD
4" Lift, 4.56's, 33" Duratracs on M/T Classics
RR SYE, Tatton CV, MML, BL, TT, Dynomax Exhaust
Hella Lighting: Driving, Fogs and H4 E-Codes
NOPE! ... and NEVER will be...
TnDz TJ is offline   Quote Quick Reply
Old 09-18-2012, 12:31 AM   #27
Jeeper
 
Join Date: Oct 2011
Posts: 17
Quote:
Originally Posted by TnDz TJ View Post
Thanks... the only concern that comes up is flow... is there a difference? HMMMMM....
I think the body diameter of the converters are the same size, and they just taper down to the different O.D's. Because you will be cutting all the pipe off and a bit into the tapered sections, the result will be an opening larger than the outlet diameter and your head pipe diameter, no matter what the O.D. was of the cat you purchased.

After writing this, I'm now remember thinking the 2" O.D. might have been a better choice because of how large the outlet was after trimming the cat. I think there would have been a little less work tapering the trimmed cat down to the 2.25" O.D. head pipe, because the trimmed outlet size would have been smaller and closer to the head pipe diameter.
tpeerson is offline   Quote Quick Reply
Old 09-18-2012, 06:23 AM   #28
Jeeper
 
TnDz TJ's Avatar
 
Join Date: Apr 2011
Location: Reno, NV
Posts: 2,925
Images: 220
Makes sense... I was thinkin along that line... just considering a flow factor. I am wondering if the the only difference in flow rate is the ID of the inlet and outlet. If that is the case, there would be no harm in getting the 2" OD and working from there.

__________________
~Todd~ 2004 X 4.0 5 speed---SOLD
4" Lift, 4.56's, 33" Duratracs on M/T Classics
RR SYE, Tatton CV, MML, BL, TT, Dynomax Exhaust
Hella Lighting: Driving, Fogs and H4 E-Codes
NOPE! ... and NEVER will be...
TnDz TJ is offline   Quote Quick Reply
Reply

Tags
catalytic , converter , p0432

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Jeep Wrangler Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
If you do not want to register, fill this field only and the name will be used as user name for your post.
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off



» Rates
Get low rates on auto insurance in Canada!

» Network Links
»Jeep Parts
» Featured Product

All times are GMT -5. The time now is 08:48 AM.



Jeep®, Wrangler, Liberty, Wagoneer, Cherokee, and Grand Cherokee are copyrighted and trademarked to Chrysler Motors LLC.
Wranglerforum.com is not in any way associated with the Chrysler Motors LLC