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Threaded steel "insert" tore off catalyst when replacing O2 sensor - help!
Posted 24 May 2004 - 11:12 AM
A new catalyst from Subaru is really expensive, so what are my options:
(1) Buy a new catalyst from Subaru?
(2) Would a welding or muffler shop be willing to weld the threaded insert back onto my old catalytic converter, or are shops unwilling to repair an old catalyst?
(3) Is there a threaded insert that I can buy to fix this (if this seems to not be an unusual problem when replacing O2 sensors)
(4) If there are no other options, where else can I go to get a replacement catalyst other then the dealer? So far I haven't found anyone who can even special order a replacement catalyst for me (one that uses two O2 sensors).
Any other options?
In the mean time, I plugged the hole in the catalyst by using a 1/2-inch national pipe thread (NPT) tap to apply a couple of threads in the catalyst and inserted a 1/2-inch pipe "plug," and unplugged the old (rear) O2 sensor from the harness and removed it completely. The car runs fine (as good as it did prior to my attempted fix), and the OBD-II scanner I have did not reveal any new codes as a result of the sensor removal (other than the previous P0420 catalyst efficiency code which was the reason for replacing the O2 sensor to begin with). As far as I can tell, the OBD-II system doesn't seem to mind that the sensor is gone, but this is a short-term fix to make the car driveable, I do want to pursue a permanent fix.
Posted 24 May 2004 - 12:53 PM
Or buy a new Sube cat. The money you might be able to save by buying a non-OE cat will be offset by the frustration of discovering that the cheap part doesn't fit right.
Get new gaskets for all the sections you intend to disconnect.
Posted 24 May 2004 - 12:55 PM
Posted 24 May 2004 - 02:58 PM
Posted 24 May 2004 - 09:33 PM
The FRONT O2 sensor is the primary instrument that the computer system uses to constantly adjust the fuel mixture of the engine.
The REAR O2 sensor is used to monitor the performance of the engine, and is the primary monitor for the performance of the catalytic converter. If the front sensor, catalytic converter, or possibly other items were to become worn out or miscalibrated, but still operable (but perhaps short of failure), the rear O2 sensor would sense an incorrect fuel mixture and signal a failure code in the OBDII system.
Again, you can drive it, but will be lacking amn important monitor of engine component miscalibration/failure.
Personally, I would get it fixed soon, but I wouldn't lose any sleep over it - don't sweat it, and I would go for the lower $$ cost solutions if at all possible.
Posted 24 May 2004 - 09:35 PM
Let us know, know I'm really curious!
Posted 24 May 2004 - 10:59 PM
I am doing my 90k next weekend and just today was considering replacing the O2 sensors as maintenance. Necessary?
How long does the manual suggest warming up the engine for before attempting removal?
As for your sensor, if the metal around the damage is in good shape I would weld (or find somene to weld) the mount back to the exhaust or mount a new one (perhaps in a different location) as NOMAD suggested. But before doing any of that, looking into the exhaust for a problem that might have triggered the error is certainly a good suggestion.
Do any manuals have tolerances for the sensors, or electrical tests that can be performed? Wondering if I can do an "inspection" of the sensors to see if replacement is necessary. Thoughts?
Posted 25 May 2004 - 05:52 AM
Posted 25 May 2004 - 06:46 AM
Sometimes the O2 sensor breaks. There is often nothing simple about it.
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