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I threw a CEL code for the O2 sensor yesterday, cleared it and about 5 mins later my exhaust got much louder. When I could inspect it, I found the post cat O2 sensor hanging from its wire having detached from the cat itself. So it broke away from the cat with the sensor still screwed in to the cat mount. Just looks like the metal or a weld failed - uuugggghh!
So these are stainless AWE cats and wasnt expecting something like this to happen. Can a good welding/muffler shop reattach the mount to the cat? Or am I screwed and need to get new cats as the weld wont hold or it will interfere with the O2 sensor itself and I will continue to throw codes? Will probably pop around to a couple of shops but interested in any opinions
I'd call AWE first, that seems to be a bad/thin weld. I don't think it's been deformed from an impact then sheared off in the process. I think you'd feel something if you hit it. I can't imagine they get one back very often. I'm sure a fabrication of muffler shop could weld it back no problem. But I'd call first.
Thanks, yes I will call them tomorrow - supposed to be gteed for life but I am not the original purchaser. I dont think anything hit the piece as I probably would have heard something that forceful. Its came off flush with the cat so prob a bad weld - what a PITA
That’s exactly what a lifetime guarantee is for. I’d call them first, before I asked at a muffler shop.
Thats been cracked and leaking for a while, as evidenced by the soot on one side. What is the papery-looking stuff onArt of the mating surface?
Will be calling them today. But the papery stuff is actually metal and presumably the welding material. And agree it does look like its been leaking for a while and then just let go at the weld. I presume the brownish area is a little rust and thats where it was leaking. So now there is a big *** hole in the cat and it sounds like a stock car
Well I certainly see them as they are right on the left side of the pipe on the bottom (or right side of pipe on the top). Right where the O2 sensor screws in, the weld is angled on to the cat
I don't see any curved small tubes like the one that broke.
You are thinking these are not AWE CAT's? That weld doesn't look like stainless. They use Stainless steel to weld Stainless steel and it doesn't rust. Also the nuts are all rusted. Why would you use carbon steel nuts on an O2 sensor in a stainless CAT. Something is off here.
You are thinking these are not AWE CAT's? That weld doesn't look like stainless. They use Stainless steel to weld Stainless steel and it doesn't rust. Also the nuts are all rusted. Why would you use carbon steel nuts on an O2 sensor in a stainless CAT. Something is off here.
Why is something "off here"?? Stainless can and does rust sometimes as witnessed by numerous threads here on what a pain some of this hardware can be to get off. Maybe thats not rust on the weld, who knows.
With respect to the O2 sensor, many 200 cell cats can/do throw CEL codes (even if some manufacturers claim they dont) and therefore a spacer was added to the sensor to eliminate the CEL's. I presume that these spacers came with these nuts and I guess they werent stainless
As to whether these are AWE cats (why i would spend my time making up this story i have no idea) here is a pic of the AWE plate that is welded on to the cats....
Originally Posted by wolfsburgde
OK, I think I see that joint now. Why do you have the elbow on the O2 sensor?
As mentioned above, its the spacer which is curved so it fits in the limited space in there. Also I added a pic (tough to get the camera up in there so its not great) and you can clearly see the weld came apart right over the hole for the O2 sensor and that hole seems perfectly round to me ie the weld just failed over time and finally just let go yesterday
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Is this fixable?
