Lex
Founding Member
Gutting the catalytic convertor
For anyone with power loss and hasn't gutted their catalytic convertors...
Ok. so for the past few weeks with a guttless car, no power on the highways or hills for that matter and the feeling that I was towing a trailer behind. I finally found out the problem. I thought it was a tranny for the longest. But this weekend I gutted both catalytic convertors. For my car (1990 2.3L LX N/A) there is 2 catalytics). The one that was plugged 90% was the closest one to the engine. Probally due to the fact that its the first to get hit with all the crap coming out of my engine. I scanned a sample of the honey type cone stuff that makes a catalytic convertor. Heres how a convertor inside should look like.
and heres what 90% of mine looked like inside
I'm not too sure what cause such plugging but I did have a tranny fluid leak into the vacuum lines which leads to the intake, so I suspect it was some of the problem.
For any of thoses who care how I did it then read on. I did get some hints and tips from some here at the forum so I thank you. NOTE: make sure to have good ventalation and wear a mask!
1) I un bolted the flang from the mainfold and the flang from the pipe to the muffler
2) I took off the pipe that has both cats attached to it
3) To save time I only cut the pipe in 2 areas to access the inside of the cats. In the center of both looked sorta like ( | = the cuts I made)
{Manifold}=pipe={catalytic1}=|==pipe==|={catalytic2}=pipe=={muffler}
4) I marked the pipe with a file in one spot where I was cutting the pip so when I weld the cat back to the pipe, I could use the line as a guide to make sure I line the pipe and cat backup as acurate as possible.
5) After I made the 2 cuts (cutted close to the opening of the cat) I locked down the catalytic convertor in my vice (the cutted end up), took a long large flat head screw driver (a long punch would work too) and started chiseling the honey like cone inside.
6) Took a bit of time but the stuff shatters pretty good and fell out farely easy. For the smaller cat (closest to the manifold) theres 2 rubber bands you have to take out (I use long needle nose plyers), and the larger cat (closest to the muffler) theres one rubber band and a wire mesh you have to remove.
7) After the both catalytic convertors were gutted, I lined them up to the guide lines I marked off earlier, and welded each cat to pipe. (if you don't have a welder you can use a piece of pipe thats a little bigger and use muffler clamps)
8) I then bolted the pipe back to the manifold and muffler pipe ( I had to get a new universal flange for the manifold). Finished!
It took me one hour with my brothers help to finish this job.
I got all my horse power back (as much as you can get for a 2.3 heehee), The cars a bit louder but more like a muscle car sound
, But it was my problem all along for the power loss. My car did stall a couple times starting up after the job, but its like it had to adjust to the free flowing exhaust. Since that job I've restarted my car with no stalls at all. To be honest you probally only need to gut the smaller one up front to the manifold as thats the one that gets hit the hardest. I just did the other one cause everything was down to do anyways and I wanted a bit more power 
.
Anyways my Dad is the one who suggested this as I thought it was a tranny problem. He told me the problem is like if you covered your mouth, and one nostril and tried running your house 5 times only breathing threw 1 nostril, thats how my car felt. Anyways thanks for all your input. it really helped 
.
For anyone with power loss and hasn't gutted their catalytic convertors...
Ok. so for the past few weeks with a guttless car, no power on the highways or hills for that matter and the feeling that I was towing a trailer behind. I finally found out the problem. I thought it was a tranny for the longest. But this weekend I gutted both catalytic convertors. For my car (1990 2.3L LX N/A) there is 2 catalytics). The one that was plugged 90% was the closest one to the engine. Probally due to the fact that its the first to get hit with all the crap coming out of my engine. I scanned a sample of the honey type cone stuff that makes a catalytic convertor. Heres how a convertor inside should look like.
and heres what 90% of mine looked like inside
I'm not too sure what cause such plugging but I did have a tranny fluid leak into the vacuum lines which leads to the intake, so I suspect it was some of the problem.
For any of thoses who care how I did it then read on. I did get some hints and tips from some here at the forum so I thank you. NOTE: make sure to have good ventalation and wear a mask!
1) I un bolted the flang from the mainfold and the flang from the pipe to the muffler
2) I took off the pipe that has both cats attached to it
3) To save time I only cut the pipe in 2 areas to access the inside of the cats. In the center of both looked sorta like ( | = the cuts I made)
{Manifold}=pipe={catalytic1}=|==pipe==|={catalytic2}=pipe=={muffler}
4) I marked the pipe with a file in one spot where I was cutting the pip so when I weld the cat back to the pipe, I could use the line as a guide to make sure I line the pipe and cat backup as acurate as possible.
5) After I made the 2 cuts (cutted close to the opening of the cat) I locked down the catalytic convertor in my vice (the cutted end up), took a long large flat head screw driver (a long punch would work too) and started chiseling the honey like cone inside.
6) Took a bit of time but the stuff shatters pretty good and fell out farely easy. For the smaller cat (closest to the manifold) theres 2 rubber bands you have to take out (I use long needle nose plyers), and the larger cat (closest to the muffler) theres one rubber band and a wire mesh you have to remove.
7) After the both catalytic convertors were gutted, I lined them up to the guide lines I marked off earlier, and welded each cat to pipe. (if you don't have a welder you can use a piece of pipe thats a little bigger and use muffler clamps)
8) I then bolted the pipe back to the manifold and muffler pipe ( I had to get a new universal flange for the manifold). Finished!
It took me one hour with my brothers help to finish this job.
I got all my horse power back (as much as you can get for a 2.3 heehee), The cars a bit louder but more like a muscle car sound
, But it was my problem all along for the power loss. My car did stall a couple times starting up after the job, but its like it had to adjust to the free flowing exhaust. Since that job I've restarted my car with no stalls at all. To be honest you probally only need to gut the smaller one up front to the manifold as thats the one that gets hit the hardest. I just did the other one cause everything was down to do anyways and I wanted a bit more power .Anyways my Dad is the one who suggested this as I thought it was a tranny problem. He told me the problem is like if you covered your mouth, and one nostril and tried running your house 5 times only breathing threw 1 nostril, thats how my car felt.
Anyways thanks for all your input. it really helped .
