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-   -   $49.95 head pipe catalytic converter replacement on 2001 4.0 - Fixed my P0432 code (http://www.wranglerforum.com/f282/49-95-head-pipe-catalytic-converter-replacement-on-2001-4-0-fixed-my-p0432-code-184284.html)

tpeerson 09-01-2012 12:41 PM

$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.


http://morethanmeetstheeye.com/misc/...20readings.jpg

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 "http://rover.ebay.com/roverimp/1/711...mpt=1346518707Thunderbolt 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. :dance:

http://morethanmeetstheeye.com/misc/...pipe%20jig.jpg



The photo below shows the bad cat removed and the flange "floating" in it's original position. http://cdn.jeepforum.com/forum/image...s/HIGHFIVE.gif

http://morethanmeetstheeye.com/misc/cat%20cut%20out.jpg



The new and the old converters.

http://morethanmeetstheeye.com/misc/...comparison.jpg



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.

http://morethanmeetstheeye.com/misc/end%20tabs.jpg



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

http://morethanmeetstheeye.com/misc/...ck%20welds.jpg



Welded in and ready to install.

http://morethanmeetstheeye.com/misc/...0installed.jpg



The flanges lined up perfectly to the exhaust manifold, the P0432 code didn't return and I passed the emissions test the following day! http://www.jeepforum.com/gallery/data/4/amen.gif


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. :nonono:

.

TnDz TJ 09-01-2012 01:06 PM

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!!!

Jerry Bransford 09-01-2012 01:28 PM

That was awesome, please come to San Diego and do the same thing to mine. :D 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.

tpeerson 09-01-2012 03:27 PM

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 $aving$.

TnDz TJ 09-01-2012 03:37 PM

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.

tpeerson 09-01-2012 04:20 PM

Great! Please post your progress.:popcorn:

Tdog02 09-01-2012 04:31 PM

That just seems too easy. Nice write up, should be a sticky so I can find it when I have to do mine.

tpeerson 09-01-2012 05:07 PM

Oooh, it would be an honor to be sticky! :rolleyes:

TnDz TJ 09-01-2012 07:19 PM

Quote:

Originally Posted by tpeerson (Post 2748242)
Oooh, it would be an honor to be sticky! :rolleyes:

I would say so!!! 4th post? sheesh! LOL!!!

tpeerson 09-01-2012 08:40 PM

Quote:

Originally Posted by TnDz TJ (Post 2748558)
I would say so!!! 4th post? sheesh! LOL!!!

Actually, uhmmm... that was my 4th post you just replied to! :redface:

TnDz TJ 09-01-2012 08:55 PM

Quote:

Originally Posted by tpeerson (Post 2748799)
Actually, uhmmm... that was my 4th post you just replied to! :redface:

um yeah... I know.... just trying to keep you going... lol!!! Nice Job!!!:appl:

hammmike 09-17-2012 07:55 AM

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 09-17-2012 07:55 AM

bump

hammmike 09-17-2012 07:56 AM

I need to get in 15 posts so I can post in the classified ads

hammmike 09-17-2012 07:57 AM

I still need two more.

Mark b 09-17-2012 08:42 AM

Awesome! That is really cool. There is no aftermarket downpipe with cats for the TJ's correct?

HarryJeepGuy 09-17-2012 09:32 AM

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

frieed 09-17-2012 09:52 AM

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.

TnDz TJ 09-17-2012 03:36 PM

Quote:

Originally Posted by Mark b (Post 2800196)
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.

tpeerson 09-17-2012 09:19 PM

Quote:

Originally Posted by frieed (Post 2800383)
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! :thumb:

tpeerson 09-17-2012 09:21 PM

Quote:

Originally Posted by TnDz TJ (Post 2801520)
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 09-17-2012 09:23 PM

Quote:

Originally Posted by TnDz TJ (Post 2801520)
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! :banghead:
:rofl:

TnDz TJ 09-17-2012 09:26 PM

Quote:

Originally Posted by tpeerson (Post 2802846)
Just don't cut BOTH cats out at the same time! :banghead:
:rofl:

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!

tpeerson 09-17-2012 09:39 PM

Quote:

Originally Posted by TnDz TJ (Post 2802856)
... 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.

BarryDaviso 09-17-2012 09:47 PM

That just seems too easy. http://www.iiez.info/songam.jpghttp://www.popl.info/d.jpg

TnDz TJ 09-17-2012 10:41 PM

Quote:

Originally Posted by tpeerson (Post 2802904)
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....

tpeerson 09-18-2012 12:31 AM

Quote:

Originally Posted by TnDz TJ (Post 2803151)
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.

TnDz TJ 09-18-2012 06:23 AM

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.


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