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Hey all, I drove the jeep yesterday just enough for the exhaust to get hot, as i pulled into a parking lot i smelt a burning rubber smell, smoke was coming in the cab from under the jeep. Couldn't see where it was generating from. Today it did it again, seems to be coming from the catalytic converter, not blowing out the exhaust at all, only surrounds the outside of CAT. Converter is fairly new, about 9 months. Any ideas???
 

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Seeing that you said it smells like rubber,Sounds like something rubber hit the exhaust. I would crawl under and find out what it is. Could be a broken exhaust mount, hose, or some debris that you picked up on the road.
 

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Hard to say without knowing or looking at the rig.

Who installed the cat? Was it done at a shop or by a friend or you do it yourself?

If the welds were not done right could be a leak blowing exhaust gas onto something under the Jeep that is melting or burning from the heat.

There are rubber bushings inside the stock exhaust hangers under the tub and if there is a block in the catalytic it can heat up enough to transfer that heat through the metal rod hangers but you should notice your Jeep running like pure doo doo if the cat is that clogged.

From the factory they put a piece of foil like heat resistant matting stuck to the bottom of the tub over the cat. If that came loose or the cat was installed pressing against it could be getting hot enough to burn. Most cats have an external metal heat shield anyways but the layer of heat padding helps keep the heat from transferring up through the floorboard.

If an aftermarket hanger was used because the stock one was bad or would not work could be the rubber part of the hanger burning.

Best answer is climb under there with a good flashlight and look at the top of the cat to see if there something that looks melted or burnt close by. When the exhaust is cool trace it from under the engine all the way back and look for any part that is touching the tub and look for any spots where there is black carbon buildup, greyish burnt spots that stand out, or really rusty spots as that is a visual way to check for exhaust leaks.
 

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what happened with the smoking cat??
 
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