Removing Catalytic Converter

[Pstallo]

Planning on swapping out my CAT for an M&K pre muffler tomorrow. Before I get started, does anybody have any tips/shortcuts on removing it?

For those who have installed a cat bypass, did you put that protective guard plate back on or leave it off?

[mark4ton]

have a torch handy to heat up the tough bolts and coat the bolts with anti-seize when you put it back together.

[Cattler]

This took me a while due to rusted bolts. Here are a few tips:

• a dremel tool with the fiberglass reinforced circular cutting blades is really helpful to remove the cat protective cover. Its not going back on, so no problem if you need to cut it or the support straps.
• expect your cat bolts to be rusted over. Soaking in PB Blaster and using heat works some. In the end, I paid a shop to break them free and replace with my hardware.
• Its possible to pay someone to do that, but you'll need to do the cat replacement yourself.
• Buy a new oxygen sensor and install it in the M&K premuffler. Who knows when the one that's in there was last replaced? Why bother trying to break it free?
• Save the old cat. You might need it someday and they're not worth much in resale anyway. I just left my old O2 sensor in it.
• Expect a bad smell for ~200-300 miles while the M&K burns out all of its chemical protectants.

Enjoy,
Dave

[chrisbruck]

The O2 sensor was the booger for me.... that old sucker wouldn't budge and I stripped it so had to pony up for a new one. The other nine or so bolts I went ahead and replaced so the "stuck" ones I just dremeled off.

[Jesse16]

I did not put the heat shield back on, should be less hot anyway.

[Brando]

Use new stainless hardware including washers & split washers. If you have to swap anything back (like, emissions testing) it will make your life much, much easier.