My '97 5.9l gasoline truck recently had a misfire issue that I have since corrected. But now, the c/c has a nasty rattle sound to it, and its not the heat shield. Sounds like marbles inside. The c/c on my truck is a 2-into-1 style. I never have smog-tests to worry about where I live, so what are my options? I am the original owner of this truck with 238,000 miles. No part of the exhaust system has ever been replaced, and I have no codes. Truck runs great, but is noisy with this c/c issue. Please advise on my options...

 

Wow, still stock? Incredible.

Option 1: Replace with OEM cat $$$
Option 2: Replace with Magnaflow kit $$
Option 3: Hack it off or gut it $

 

Sounds like the media inside the converter is breaking up and going bad. Sounds like its time to replace the converter. Easiest thing to do is to purchase a replacement converter, have the old one cut out by a competent muffler shop and weld the new converter in its place. I recently had this done on my truck and used Magnaflow converter 99047HM as the replacement converter. This allowed me to run 3" exhaust from the converter on back. I also replaced the muffler with Dynomax UltraFlo 17233. Hope this helps.

 

There was a recall on some years(96 for sure) because it broke apart. This is what mine looked like. Put on a magnaflow and very happy with it.

 

If that plugs your cat or muffler, you'll be a lot worse off. Replace it.

 

Will I have a CEL if I just totally eliminate the c/c? The O2 sensors are original too, and they're pretty rusty so I know I'd be replacing them too if I attempt to remove them. I'm not wanting to have CEL, but I'm not wanting to spend much money either.

I'm a welder by trade, so I have access and knowledge for all sorts of cutting tools and welding equipment

 

Its a crap shoot. Might get one, might not.

 

If you are a good welder, I would certainly cut out the old cat and weld in a new one. You can find a new converter on eBay for under $100 delivered within the US. The front O2 sensor goes into the cat, so purchase a new front sensor, too and do some cutting and welding - this is what the muffler shop would do.

 

I calle dmy local dealer and he ran my VIN and apparently no recall on my truck.


Is it also an option to just cut a hole into the side of the c/c, empty out the contents, and then weld up a patch onto the side to reseal it? That won't set a code? That's what I'm leaning towards as it won't cost me a dime.

(Fyi, even the muffler is factory on my truck! It does have a rusted out hole in the bottom, but still sounds nice and quiet like the day I drove it off the dealer's lot.)

 

Yep, you can do it that way as well, but, still, the code may or may not set. I think I have seen one once in my truck, and it hasn't had a cat since before I owned it. The newer trucks seem to be more picky.