Exhaust to Cat Converter connection - Taurus Car Club of America : Ford Taurus Forum
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post #1 of 24 (permalink) Old 04-29-2014, 03:45 PM Thread Starter
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Exhaust to Cat Converter connection

The connection from manifold exhaust and cat converter started to come loose and get noisy. Engine light also came on and test from mechanic indicated it was Catalytic error. (Probably from being loose) He wanted to replace with new for $1200 which I declined. Since then, exhaust came apart in driveway (I tempted fate for too long). I got under and saw that flange from cat side was gone as was the mesh shield and, what looks like a large spring around pipe, is broken. I pushed pipe directly into exhaust pipe and after disconnecting battery to reset errors, engine light is now out and car sounds fine.
Now, I know I can't drive it but what do I need to connect the two back up? Welding is not an option for me but can I attach a short flex pipe with a flange to exhaust and clamp other side to Cat pipe?
Also, clamps/holders are gone and I'm not sure what type or where to attach new ones.
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post #2 of 24 (permalink) Old 04-29-2014, 07:21 PM
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Hard for me to follow exactly what the options are without some good photos.

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post #3 of 24 (permalink) Old 04-29-2014, 07:29 PM
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A local muffler shop made me the pipe you are tallking about and installed it (with the mesh shield) for $125 Cdn. It was a common job for them. You could start there. They used a stock shield and pipe and then welded the proper size flange to it that bolted right on.
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post #4 of 24 (permalink) Old 04-29-2014, 09:06 PM
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Check on ebay, (Ford Taurus/Mercury Sable Exhaust Flex Pipe w/OE Flange) there is a company that sells a repair kit which I bought for my 2006 two years ago for the same issue. You then buy a stainless band clamp for stepped connections and your set. Your set for less that $40.
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Last edited by Automender12345; 04-29-2014 at 09:09 PM.
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post #5 of 24 (permalink) Old 04-30-2014, 01:47 PM
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I was told that you can not use a clamp on the converter, or it will fail testing. Is that true?
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post #6 of 24 (permalink) Old 04-30-2014, 01:51 PM
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Quote:
Originally Posted by whynot162 View Post
I was told that you can not use a clamp on the converter, or it will fail testing. Is that true?
thats the first time i've heard of it...as long as its on the car and doesn't have any leaks. it doesn't matter if its clamped or welded.

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post #7 of 24 (permalink) Old 04-30-2014, 02:34 PM Thread Starter
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That looks like exactly what I need. I'll give it a try.
Thanks
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post #8 of 24 (permalink) Old 04-30-2014, 02:38 PM Thread Starter
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Quote:
Originally Posted by Automender12345 View Post
Check on ebay, (Ford Taurus/Mercury Sable Exhaust Flex Pipe w/OE Flange) there is a company that sells a repair kit which I bought for my 2006 two years ago for the same issue. You then buy a stainless band clamp for stepped connections and your set. Your set for less that $40.
Band clamp may just do the trick. I'll try it, thanks.
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post #9 of 24 (permalink) Old 04-30-2014, 03:17 PM
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so the guy at the parts store is full of.... and I can clamp one on. Thanks,
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post #10 of 24 (permalink) Old 04-30-2014, 05:47 PM
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Originally Posted by whynot162 View Post
so the guy at the parts store is full of.... and I can clamp one on. Thanks,
I know that they used to look underneath with a mirror for tampering when doing tailpipe emissions testing here in Ohio, haven't seen them do it on newer OBDII vehicles when they just hook up to the DLC.

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