how to fix a failing catalytic converter in Ford Explorer Fifth Generation (2011-2019)

Ford Explorer Fifth Generation (2011-2019)

Error Codes

2-4 hours

Time

medium

Difficulty

high

Severity

3 min read

561 words

⚠️ Safety Warning

This issue requires immediate attention. If you are not experienced with automotive repairs, consult a professional mechanic. Working on critical systems can be dangerous.

Problem Statement

Learn how to diagnose and fix a failing catalytic converter in Ford Explorer (2011-2019). Step-by-step guide with symptoms, diagnostic steps, and repair instructions.

Affected Component

Exhaust System

Estimated Time

2-4 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Disconnect the battery before working on electrical systems.
•Allow the exhaust system to cool before working to avoid burns.

Symptoms

•Check engine light illuminated
•Decreased acceleration and power
•Engine stalling or rough idling
•Unusual exhaust odors (e.g., sulfur smell)
•Poor fuel economy
•Increased emissions

Diagnostic Steps

1
Scan for error codes using an OBD-II scanner to identify potential catalytic converter faults.
2
Inspect the exhaust system visually for any signs of damage, leaks, or blockages.
3
Check the upstream and downstream O2 sensors for functionality and proper readings.
4
Measure exhaust backpressure to ensure it is within specifications.
5
Perform a visual inspection of the catalytic converter for signs of physical damage or overheating.

Solution

💡 Expert Tip

For complex repairs like this, consider taking photos at each step. This helps if you need to reverse a step or consult with a mechanic. Also, keep all removed parts organized - you may need to reference them during reassembly.

Verification

After completing the repair, verify that the issue has been resolved:

✓Test the affected component to ensure it functions correctly
✓Check for any error codes or warning lights
✓Monitor the vehicle for a few days to ensure the issue does not recur

Prevention Tips

To prevent this issue from occurring again:

•Follow the manufacturer's recommended maintenance schedule
•Address warning signs early before they develop into major issues
•Use quality parts and fluids recommended for your vehicle
•Keep detailed records of all repairs and maintenance

Tools & Equipment Required

•OBD-II scanner
•Socket set
•Jack and jack stands
•Safety glasses
•Gloves
•Wrench set
•Torque wrench
•Penetrating oil

Parts Required

•New catalytic converter
•Exhaust gaskets (if needed)
•O2 sensor (if needed)

Related Faults

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Diagnostic Steps

1
Scan for error codes using an OBD-II scanner to identify potential catalytic converter faults.
2
Inspect the exhaust system visually for any signs of damage, leaks, or blockages.
3
Check the upstream and downstream O2 sensors for functionality and proper readings.
4
Measure exhaust backpressure to ensure it is within specifications.
5
Perform a visual inspection of the catalytic converter for signs of physical damage or overheating.

Solution

1. Preparation

Tools Required: OBD-II scanner, socket set, jack and jack stands, safety glasses, gloves.
Safely raise the vehicle using a jack and secure it with jack stands.
Disconnect the negative battery terminal to prevent electrical issues during repair.

2. Remove the Catalytic Converter

Tools Required: Wrench set, penetrating oil, torque wrench.
Apply penetrating oil to the bolts securing the catalytic converter to make removal easier.
Remove the bolts from the catalytic converter using the appropriate size socket or wrench.
Carefully detach any hangers or brackets supporting the converter.
Take out the catalytic converter from the exhaust system.

3. Inspect and Prepare New Catalytic Converter

Inspect the new catalytic converter for any defects before installation.
Ensure that the new catalytic converter is the correct part for the specific model year and engine type.
If applicable, transfer any necessary sensors or gaskets from the old converter to the new one.

4. Install the New Catalytic Converter

Position the new catalytic converter in place and secure it with the original or new bolts.
If required, use a torque wrench to tighten bolts to manufacturer specifications (typically around 30-35 ft-lbs).
Reattach any hangers or brackets that were removed during disassembly.

5. Reconnect Battery and Test

Reconnect the negative battery terminal.
Start the engine and let it idle for a few minutes to check for any exhaust leaks.
Conduct a test drive to ensure the vehicle performs normally and the check engine light is off.