catalytic converter PO420 code 96Windstar

[wisechoice]

Check engine light resulted in at PO420 code, apparently the catalytic converter has gone bad. $1425 quote from the dealer to repair. How long can I go without repairing it? I'm afraid this vehicle will nickle-dime me with 140,000k on it!

[garync1]

IF your state pulls codes for inspection then that about how long you have.If your cat is really cloged it can blow a exhaust gasket. Also fuel mpg will go down. Loss of performance and excess stress on the motor.If it seems to be running ok now than you may be able to get by with it for a few months. Im sure the local muffler shop will be alot cheaper than the dealer. The dealers like to sell you cat all the back to the muffler. I thinking no more than 200.00 from a muffler shop.It could be a touch higher than that. I would check online for the cat to see how much the part will be, then add labor and you can get a good idea about the price.

[garync1]

well your cat will run you about.
WALKER Part # 50406
{Direct Fit Converter
$303.89
Thats just an idea. Walker is good name brand but you may be able to find it cheaper than that. If you want to cut cost even more, look at advance or autozone buy it,take to a muffler shop they will charge you labor. Should be around 80.00 or less takes them about 30 min to do. The one shop I use, they just cut and weld. hope this helps.

With 140,000 miles its time for a new cat and maybe a muffler as well.
But anyway a muffler shop is cheaper than the dealer

[wiswind]

I have the Walker part mentioned on my '96 3.8L.
You do not have to cut & weld IF things come apart as they should. You have 2 catalytic converters.....one for the front 3 cylinders....and one for the rear 3 cylinders....
After the converters....the 2 pipes merge into 1 pipe.

I have a picture of the original and the old one side by side in my pictures at http://community.webshots.com/album/201931518cScpNK

The Walker part replaces the 1 part that includes....as shown, the pipes from each exhaust manifold, to the converters, the converters, and the "Y" pipe that takes the 2 pipes into 1 pipe.....and to the flex joint....that is just in front of the muffler.

You will need to buy 2 bolts, lock washers, and nuts to connect the back of the "Y" pipe to the flex joint....as the original is threaded.....and the walker is not.....
You also need to buy the gasket that goes in between the Flex pipe and the rear of the "Y" pipe.

You can buy these parts at www.rockauto.com....minus the bolts & nuts that I mentioned....which can be bought at any auto parts store.... Visit the rockauto site.....select the catalytic converter in the parts lookup.....and click on "Information" tab.....and you will see a breakdown of the exhaust system with Walker part numbers for the various parts.

You should be able to re-use your oxygen sensors.....a "oxygen sensor" socket will be helpful for removing and re-installing them. It has a slot on the side for the wires. I would put some Permetex Anti-seize Lubricant on the threads when installing them into the new unit. Be careful of the "downstream" sensor that is mounted into the back of the rearmost converter......mine broke right out of the back of the converter....and I had to work a while to remove the ring... without damage to the sensor. That is the only sensor that is mounted into the thin metal of the converter as opposed to the thicker metal of the pipes.

I soaked all the bolts (2 at each exhaust manifold, 2 at the flex joint in front of the muffler, and the oxygen sensor threads) with PB-Blaster and let it soak for a while before starting the job. For the oxygen sensors....soak ONLY the threads...you don't want to get it in where the wires go in......as that might damage them. They work by a chemical reaction.....caused by a difference between the oxygen level in the exhaust....and in the atmosphere.....so you don't want to seal out the atmosphere with a film of oil, etc.

Sorry about the babble on the oxygen sensors....but at over $50 each.....and you have 4 of them....... a little TLC is in order....

I had a problem with 1 of the manifold "studs".....replacements can be bought at the dealer.....cost me about $5 for one. The threads going into the manifold are different than the threads that the pipe bolts to.

A 15mm socket is your friend when working on the windstar. That is what you will need for the exhaust manifold stud nuts.

I have "a few" thousand miles on my new catalytic converters....and all is going well.

Exhaust work on pretty much any car is NOT fun.
If you have it done for you....at least you know what is involved.