91 Explorer catalytic converter questions

[jackchandler]

I have a 91 Explorer that runs fine when it is cold, but when it warms up it starts to stall out whenever I try to accelerate. It idles fine, but if I am stopped at a stop sign or red light it will stall whenever I try to give it even the slightest amout of gas. It is almost like it chokes out. We changed the fuel filter, and the idle speed motor and cleaned the iac valve. It has fuel pressure, and no vacuum leaks, so now the mechanic seems to think the cat converter is plugged. Here is the big problem...The bolts that hold the cat converter on are rusty (the car is 14 years old) and he thinks they will break if he tries to remove them, so he doesn't want to work on the car.

Does anybody have ANY suggestions on how to either

a) change it
b) bypass it
c) drill a hole in it? would that help?

What should I do, any help would be appreciated, Thanks

[zowdie]

You may want to try replacing the oxygen sensor first. If you do need to replace that catilytic converter, look at replacing it with an aftermarket system. It will save you a lot of time in the long run. Try some PB Blaster to loosen the bolts before you wrench on them. It has worked on some very tough and rusty bolts for me. If they do break, just drill the rest of it out and replace them with stainles steel. Enjoy and good luck.

[way2old]

If you can remove the O2 sensor as previous poster mentioned, drive the vehicle and see if it improves. If stalling goes away or acceleration improves, take it to a quality muffler shop and have them repair. They will quote price up front and will abide by it.