Cat Stolen - R+R - Cheaper

[Hollis]

Hi all,

Unfortunately I was targeted by the crackheads. They cut my pipe behind the O2 sensor (whew) and unbolted the back and took the catalytic converter. I did not want a weld in replacement, I wanted a direct fit bolt in part. This is on a 1997 SR5 3.4 V6 Auto 4wd (Non CA) with 189K miles
Options:

Dealer - $1500 - Available Now
Rockauto - $246 Eastern Cat - 3 Days out + extra Shipping
Oreilly - $428 - Magnaflow - 5 days out
Autozone - $304 - Walker - 1 day out
Advance - $304 - Walker - 4 days out


Got a winner! I ordered the part and commenced the gathering of Gaskets.
One at Autozone, 2 at Advance and one at Oreillys.

Pretty straight fwd R+R. I unpluged the O2 sensor. Three 14mm bolts to undo the bracket that holds the cat on near the exhaust manifold. 14mm for the 3 nuts to the exhaust manifold (I soaked the bolts and nuts with PB Blaster for a day and a half). A cheater pipe and some elbow grease broke them loose. One nut was harder to get to but luckily you can take the rubber splash guard down behind the passenger side wheel by pulling 3 of the plastic push-in tabs out with a screw driver.

With what was left of the old cat I made sure the gaskets were correct then removed the O2 sensor by the two 12mm nuts. I taped up the sensor end. I then sanded most of the rust and scale off the gasket mating surface of the O2 sensor. Removed the tape, put the new gasket over the studs and put the old O2 sensor on the new Cat.

Under the truck, I started from the back and eased the collector flange side over cross member and twisted it a little to get it into place being cautious with the O2 sensor. A little finess got it in.

I lined the holes up with the studs at the collector, put one nut on hand tight and moved to the back. In the back, I put the new gasket on, brought the hanger up to flanged connection and I put my new SS 5/16 1" bolt and washers through. On the back up, a lock washer and nut and left them loose enough for some play. At the front end, I put the other 2 exhaust nuts on hand tight, then the bracket. All are 14mm. I slipped in the 2 exhaust gasket through the wheel well where I dropped the splash guard. Make sure you seat them correctly.

Assuring everything was correct I tightened everything down tight. I put a little dielectric grease in the O2 sensor connection and connected it. Placed the 3 plastic push tabs into place to hold the splash guard up and done!

Without running around only took about 2 hours.

Here is the parts list:
Autozone - Walker direct bolt in Catalytic Converter PN# 53287- $303.99
(with a $40 Mail in rebate Valid 9/1/11 - 10/31/11) Sweet!
Autozone - Fel Pro Exhaust Flange Gasket (Cat to Muffler pipe) PN#61039 - $3.99
Advance Auto - Fel Pro Cat Conv Gasket (Cat to Manifold)(x2) PN# 23591- $5.98
Oreilly - Dorman/ Help O2 Sensor Seal PN# 47021 - $3.99
Home Depot - 2 SS 5/16 x 1" bolts, 2 SS washers, 2 SS Lock Washers, 2 SS nuts - $3.92

Total with tax in Texas =$348.42 - $40 (Mail in Rebate on cat) = $308.42

Thanks for reading

.__________________
1997 4Runner SR5 4wd 3.4 V6 Auto
Running board delete, Bone stock drivetrain, front tint, alarm, Poly sway bar bushings, Yoko Geolander HT/S, rusted through back bumper, New Walker catalytic converter (not by choice)

 

[chrismgon]

Very informative! Though, I just got mine finished yesterday, and before doing it, I would have not had a clue what you were saying. I learned alot and what you wrote makes perfect sense. Thanks!

Did you have any Check Engine Lights on after the install?
Did you notice much of a difference in the sound/power?

You will not believe how badly I stripped that hard to get to bolt from cat to exhaust manifold. I did not realize it was hiding behind that splash guard till too late. Though it was so badly rusted, I had to use an Impact Wrench on all nuts.

I drove around today for the first time since replacing cat/muffer/tailpipe afor about 108 miles. Although I was nervous as hell and expecting something to go wrong, all was good. Except a bit of exhaust leak up front (need to tighten probably) and a louder muffler sound.

Btw, know the torque specs for those 3 nuts going to the exhaust manifold?

 

[TheDurk]

Good info. It would be nice if you posted year, engine and whether Cali. or 49-state (if '99 or '00) so that people would know if you are the same application as their own truck. I'm guessing you are a '96-'98 or a '99-'00 49-state since you only mention one cat, but it would be nice to confirm.

Most of us put our truck specs in our sig.

 

[Hollis]

Very informative! Though, I just got mine finished yesterday, and before doing it, I would have not had a clue what you were saying. I learned alot and what you wrote makes perfect sense. Thanks!

Did you have any Check Engine Lights on after the install?
Did you notice much of a difference in the sound/power?

You will not believe how badly I stripped that hard to get to bolt from cat to exhaust manifold. I did not realize it was hiding behind that splash guard till too late. Though it was so badly rusted, I had to use an Impact Wrench on all nuts.

I drove around today for the first time since replacing cat/muffer/tailpipe afor about 108 miles. Although I was nervous as hell and expecting something to go wrong, all was good. Except a bit of exhaust leak up front (need to tighten probably) and a louder muffler sound.

Btw, know the torque specs for those 3 nuts going to the exhaust manifold?

Sorry, I have been busy making up all the time missed working on the truck.
I did not have any check engine lights at all. I even drove it, open exhaust, to the Parts House and back twice. I think I feel a little more power, I am sure the new cat is less restrictive. The sound is the same.
I do fill up at the exact same pump and drive nearly the same routes every week and document the gas mileage so it will be interesting to see if it gets any better. I am kind of a dork.
My truck was up north for the first 8 years of it's life so it has a little more corrosion than most down here. The bolts were a bear, I used a deep socket, about 18" of extensions and a breaker bar with a two foot cheater bar to break them loose.
I have put about 100 miles on and seems great. I was unable to weld up a cage this weekend, hopefully iI can do it next Saturday.
As far as torque specs, I put them on as tight as i could in order to seal the gaskets and not leak. I used the same tools I used to take them off.

 

[Hollis]

Good info. It would be nice if you posted year, engine and whether Cali. or 49-state (if '99 or '00) so that people would know if you are the same application as their own truck. I'm guessing you are a '96-'98 or a '99-'00 49-state since you only mention one cat, but it would be nice to confirm.

Most of us put our truck specs in our sig.

I set up my sig. 3.4V6, Non CA

Thanks