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One other possibility could be a muffler that has broken welds on the inside. I had this problem with an old Ford truck. Sometimes the baffles in the muffler would catch and it would run great, other times the pieces fell to gether and blocked the flow. You end up with the same problem KC Ron Carter outlined - too much backpressure and the cat just can't burn all of the excess.
Find a good exhaust shop to help you diagnose which part to replace before you get a lot of expensive parts melting - or just rip it all out and call Jared for the good stuff to go back with.
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