how to fix the catalytic converter issue on Ford Explorer Sixth Generation (2020-present)?

Solution

1. Preparation

• Gather tools and parts.
• Disconnect the battery to ensure safety.
• Raise the vehicle using a jack and secure it with jack stands.

2. Remove the Exhaust Components

• Tools Required: Socket set, wrench set, exhaust hanger removal tool.
• Sub-steps:
  1. Remove exhaust clamps and bolts connecting the catalytic converter to the exhaust system.
  2. Carefully detach any exhaust hangers using the exhaust hanger removal tool.
  3. Slide the catalytic converter out of its mounting position.

3. Inspect the Catalytic Converter

• Tools Required: None.
• Sub-steps:
  1. Inspect the catalytic converter for physical damage or signs of clogging.
  2. Check for any rattling noise indicating internal failure.
  3. Verify that there are no loose or broken components.

4. Replace the Catalytic Converter

• Tools Required: New catalytic converter, gaskets, exhaust clamps, torque wrench.
• Sub-steps:
  1. Install a new catalytic converter, ensuring that it is oriented correctly.
  2. Use new gaskets to prevent exhaust leaks.
  3. Tighten bolts to manufacturer-specified torque settings.
  4. Reattach exhaust hangers and ensure the system is secure.

5. Reconnect the Battery and Test

• Tools Required: None.
• Sub-steps:
  1. Reconnect the battery terminals.
  2. Start the engine and allow it to reach operating temperature.
  3. Inspect for any exhaust leaks and listen for unusual noises.