I think I just removed the original cat after 235K miles.

Zeke · 11-02-2006, 07:21 PM

Is it possible that the thing lasted that long? Of course, it's dead now, but a year ago the PO passed smog with it. I bought a DEC from Pelican to replace it. The old hardware was so bad that I couldn't even use the heating with a torch method to get the nuts off. They were so bad that I couldn't get a wrench or socket on them. I used the stinkin' cutting torch after a half hour of frustration.

And, I'm reading about which O2 sensor to use. Wil Ferch had a very good write up, but he said that there was more to be said. I couldn't find anything beyond his somewhere around 5 choices (that ought to be enough, eh?), but there was some reference to a "wide band." Huh?

I'm gonna try to sneak thru smog with the new cat and sensor. If it fails, I'll be back for a run thru of all the tricks. I've been bookmarking threads for nearly a month now. We'll just have to see what the results are. The car runs smooth as silk, but it's tired. Real tired. 235K and not a thing done to the motor. If I pass, I can get a current tag and go on the T-Day run.

That engine work will be started soon, but I'd rather not tear into it right now. I would rather buy some time with a successful smog test.

I asked Pelican to send me all the hardware needed, but they just sent the 3 gaskets. What is the preferred hardware (bolts) here for the cat to muffler? I'm gonna remove the cat right away (assuming I can pass) and put the old one back on because I don't want to load a new cat up with oil, etc and ruin it. I'll save it for when I get the valves, etc. done. I don't want to go thru this frozen nuts and bolts deal again, if I can help it. Beyond high temp anti-seize, what's the best to use?

RickM · RickM's Garage

Milt: You can go with a generic Bosch O2 sensor for a lesser price. Here's what I posted in the past.

"FWIU the proper "generic", Bosch sensor is the same sensor as OE less the specific harness plug. The generic sensors come with a well designed solderless splicing kit which you use with your own plug. I used it on four sensors for a '97 Twin Turbo and it worked perfectly."

......and......

"Pelican lists the (generic) sensor @ $79. Part # PEL-SW85-2438.

The Bosch site does show a different OE # for the 84-85 vs 86-89 Carreras. However, the Bosch generic replacement (Bosch# 15735) is the same. This is the one Pelican is most likely providing."

Typically a wide band sensor is used in conjuction with monitoring equipment after making engine or ECU upgrades. The info is is very helpful when dialing in AF ratio.

jkarolyi · 09:43 PM

Even cheaper than the generic Bosch sensor is a Bosch for an '87-89 Ford Mustang V8. About $40 at AutoZone, and mine had it in stock! It looks identical to the universal Bosch but has the wrong connector. Simply cut the connector off and solder it on the way you would the universal one.

My '89 Carrera ran great and passed smog no problem with the Mustang sensor. Mine had 145K on the original cat, by the way. Those are some tough German cats...no wonder they cost $1600 new!

HarryD · 11-02-2006, 10:11 PM

Milt,

A cat in a properly tuned car can last a long time running good quality gas. My 1993 Ford Taurus was easily passing Emissions testing at 200k when I sold it last year.

greglepore · 11-03-2006, 03:06 AM

Ditto the Ford sensor, I've used one for several years, no issues. Just cut off the connector and splice.

I used local hardware store stainless hardware-you can find the sizes by doing a search for premuffler stuff-I don't recall them off the top of my head. They were on for around 3 years and were easily removable, but were pretty galled and I didn't reinstall. I couldn't find the proper bronze nuts, which supposedly avoid the galling problem. If you're pulling them every year to swap, the basic stainless should be ok.

KFC911 · 11-03-2006, 03:34 AM

Quote:

Originally posted by milt
[i].... What is the preferred hardware (bolts) here for the cat to muffler? I'm gonna remove the cat right away (assuming I can pass) and put the old one back on because I don't want to load a new cat up with oil, etc and ruin it. I'll save it for when I get the valves, etc. done. I don't want to go thru this frozen nuts and bolts deal again, if I can help it. Beyond high temp anti-seize, what's the best to use?

I followed Wil Ferch's suggestion from a few years ago (an also used antiseaze, even though that's probably overkill) that's on this thread.
bolts for exhaust system

If you just need the three bolts and nuts for the cat/muffler, then I've got a few extra that I can send you if you want to go that route (instead of a box of 25/50 from McMaster-Carr.

Porsche_monkey · 11-03-2006, 04:25 AM

Cats don't die. They are murdered.

RickM · RickM's Garage

Quote:

Originally posted by jkarolyi
Even cheaper than the generic Bosch sensor is a Bosch for an '87-89 Ford Mustang V8. About $40 at AutoZone, and mine had it in stock! It looks identical to the universal Bosch but has the wrong connector. Simply cut the connector off and solder it on the way you would the universal one.

My '89 Carrera ran great and passed smog no problem with the Mustang sensor. Mine had 145K on the original cat, by the way. Those are some tough German cats...no wonder they cost $1600 new!

Actually you can get the proper generic for about the same price as the Mustang at places like Napa. I listed the Pelican part & price to show support for the board.

Jeff · 11-03-2006, 05:55 AM

Milt, Before you put the old cat back on, run a broom stick through it and hollow it out. If it was clogged before and not "breathing", it will now.

JeremyD · JeremyD's Garage

McMaster for nuts and bolts - I went the easier route and went to West Marine for their 316 stainless - I used their similiar sized nuts and bolts with a little antiseize and have not had any galling - even though I know that is a possibility with same ss components.

Mine were the same way though - I ended up cutting every one off with a dremel - couldn't even get a wrench to turn em with heat.

Zeke · 11-03-2006, 06:41 AM

Quote:

Originally posted by PBH
Cats don't die. They are murdered.

Not quite. Murder is intentional. A tired engine is just manslaughter.

rusnak · 11-03-2006, 05:00 PM

I think my cat had like a dozen lives. It survived for over 280K miles. I just ordered the aftermarket one that is a direct bolt in replacement. I also have a Bosch generic 3-wire 02 sensor in my spare parts supply.

My plan is to cut off the old skid plate, heat shield for the cat and for the O2 sensor, and weld it back on to the flange after I clean up the metal.
The old bolts will have to be cut off. There are 3 gaskets: one for the muffler, and two for the cat. I know that with a valve adjust it will pass smog.

Milt: a quick tip 'fer ya - get a can of "BG 44K" made by BG. Put it in a full tank of Chevron Premium. When you are down a 1/4 tank, take it in and have it smog tested. Should pass just fine, and you'll notice a lot of improvement in peformance.