universal fit catalytic converter

[danno0256]

has anyone used the universal fit cat, how much cutting,welding, and can the 02 censors be cleaned rather than replaced? 96 windstar. thanks

[wiswind]

Do a search on a thread "catalytic converter with loose insides"
I bought the Walker "Direct fit" replacement for $321 from Rockauto.
This item includes BOTH converters, the pipes to the exhaust manifolds, and the Y the bolts to the flex pipe that is just in front of the big muffler.
It has heat shields on the TOP of the catalytic converters, but not the underside.
The heat shield of the front converter is against the oil pan. The original was very close.....you have to remove the converter assembly in order to remove the oil pan.....regardless of which converter you use. I would be concerned about clearance at this point with the universal units also....

You will want to get some "PB-Blaster" penetrating oil....and soak the nuts on the exhaust manifold studs.....I would recommend that you buy 4 new nuts..... M10 x 1.5 for the exhaust manifold studs. Get the "automotive quality". You will also need to get the gasket for in between the rear pipe and the flex pipe... Also, get new nuts (Recommed bolts also) for the connection at the back also.
The factory unit had threads for the M10-1.5 x 29 bolts....the Walker did not.

The Walker unit has the fittings for the oxygen sensors, but....and you will see from my pictures...or when you look under your car.....the "downstream" oxygen sensor for the rear most converter screws into the back part of the converter.....mine broke right out. The mountings for the Walker unit....all are in the pipe.

Spray the threads of the oxygen sensors with "PB Blaster".....but do NOT soak it into where the wires go into the oxygen sensor. The oxygen sensor senses the oxygen in the atmosphere....and inside the tail pipe. The difference between the 2 oxygen levels creates a chemical reaction......so you don't want to get the oil in there.

Buy yourself a "oxygen sensor socket"....it is a deep socket with a slot up the side to accomodate the wires.

I unplugged the oxygen sensors, then dropped the converter assembly....being careful not to get hung up on the oxygen sensors......removed the sensors, and installed them into the new unit. I am still on my original oxygen sensors at 147K miles.

Pictures from my '96 3.8L.....

http://community.webshots.com/album/201931518cScpNK