Replacement catalytic converter sure didn't last long (1999 4runner)

[pendragon]

On my 1999 4runner (2.7 L 3RZ-FE 2WD), I replaced the OEM catalytic converter at 238k miles in March 2017 with an Eastern Catalytic 40685. A couple weeks ago, the new cat started rattling like rocks in a tin can. I guess it's shot. It only made it 10k miles and a little less than a year. Of course, their warranty apparently doesn't cover broken internal media, just 'manufacturing defects.' :dammit:

Catalytic converter warranties cover manufacturing defects (such as an incomplete weld). Warranties do not cover impact damage (such as hitting a curb), nor internal damage due to improper fuel mixture (which causes overheating and soot damage to catalysts). Converters have no moving parts, so defects are rare. Because mis-diagnosis often occurs, even by the best mechanics, converter manufacturers insist on inspecting parts to confirm a defect exists, before approving warranty claims.

I don't know if Eastern cats are crap, or if I just got unlucky. I guess I'll be ordering a Bosal 099236 this time. Maybe I'll be luckier with it. I'm getting 14.5 mpg, I wonder if the new cat and O2 sensors will help?

I mainly just wanted to post this to establish a data point for anybody else replacing their cat, but if anyone has something to add (why I went through this cat so fast), I'm happy to hear it.

 

[SaulG]

Depends on whether Eastern is a manufacturer or distributor..but yeah a lot of after market cats are crap..get it to pass and sell it type stuff.
Quite common for separation to happen on the "offshore" brands. 10k is pretty good.

 

[whyzee125]

Sorry to hear that! I'm sure most aftermarket cats aren't as good as OEM but I've looked into easterns as I got a p0420 for about a week this past winter so I'm expecting I"ll need to replace mine within the year. Most people seemed to have better luck than you did. Good luck with the bosal

 

[Buckaroo]

Catalytic converters die because they get overloaded due to poor running engines causing excessive emissions. This causes the honeycomb substrate to get very hot which could be the cause of your premature failure. Really, they don't die on their own....they are murdered. If you just replace the cat without solving the underlying problem, the new one could again fail quickly.

That said, aftermarket cats do not typically have the service life of an OEM cat....you get what you pay for. But, some potential things to look at:
- misfires that soak the cat with unburned fuel
- oil in exhaust due to leaking rings
- bad engine temp sensor not allowing engine to go into closed-loop operation
- bad front O2 sensor

Buckaroo

 

[JZiggy]

Catalytic converters die because they get overloaded due to poor running engines causing excessive emissions. This causes the honeycomb substrate to get very hot which could be the cause of your premature failure. Really, they don't die on their own....they are murdered. If you just replace the cat without solving the underlying problem, the new one could again fail quickly.

That said, aftermarket cats do not typically have the service life of an OEM cat....you get what you pay for. But, some potential things to look at:
- misfires that soak the cat with unburned fuel
- oil in exhaust due to leaking rings
- bad engine temp sensor not allowing engine to go into closed-loop operation
- bad front O2 sensor

Buckaroo

This. I've had this happen before and with an Eastern Cat. A car wasn't running right and so the OEM cat gave up the ghost. Replaced it with an Eastern and within a week the media had separated. The outside of the housing had a strange color pattern from getting way too hot.