Bad catalytic converter

[Hebes10]

My 2011 PP with 70,000 miles started getting a P0420 code after replacing my drive belt and tensioner ( I cant remember but maybe I accidentally hit the cat with a wrench??) . Ford service diagnosed a hole in the bank 1 catalytic converter ( I believe it’s the longer one). They quoted $2100 to replace it, but of course there are no OEM parts available nor any aftermarkets parts that Ford will install. Even if they had one in stock, $2100 seems crazy for one cat converter.

So I looked at RockAuto, and they have Davico for $350. Magnaflow has an OEM style replacement cat (#21-017) for $840. I feel like if I am going to do one cat, I might as well do both. Then downpipes start to make a lot of sense, so I was looking at PPE downpipes, which include Magnaflow high flow cats and the pair is about $1700. I do need an annual emissions inspection, which is why PPE seems to be the best option. Do I need to replace all of the O2 sensors too?

I do have Livernois 93 Stage 4 Plus 3BAR tune so I am guessing that I would need to get that updated? I am a little hesitant since I have had no problems with my current tune from them, but I am aware of recent issues. I am not racing this car, its my daily driver and occasionally like to floor it when getting on a highway or coming off a stop light. I don’t have any other mods besides what I needed for the tune, but I have kept up on all of the other maintenance.

Also, should I be concerned why the cat failed? Is whacking it with a wrench enough to break it, especially since I am not even sure I hit it?
I appreciate any input!

 

[Ta2dResqr]

No hitting it with a wrench is not what caused it. Especially hitting it light enough that you aren't even sure you did it. Ask anyone that has takenthe material out of a cat. Last one I did, I used an air hammer and a LONG chisel bit and it took forever. Honestly, on stock unmodified vehicles, I can count on one hand how many cats I had to replace without another underlying cause. I would be suspicious of the tune. Other options are leaky/faulty injectors, poor ignition, etc. Personally, if it was my car and I wanted to keep it for a long time, I would be looking at a new tuner and PPE downpipes. $575 for a tuner and a tune, $1700 for downpipes, install it yourself, and you will be better running, faster, more reliable than when you started.

 

[gwrabbit]

$2100 for replacing a single cat is absurd. My shop quoted me $800 parts + labor. If your area doesn't do emissions testing, then I wouldn't even bother with replacing the catalytic converter. My cat has been out since 89k miles and I'm now at 155k with 0 issues.

 

[76FoMoCo]

At that mileage I would replace the o2S number one's. This Will also help and most likely you will mess them up trying to get them out.
IMO PPE pipes, o2s and a new tuner/ tune.

 

[Hebes10]

The hole appeared to be caused from exterior corrosion on a weld. After removing, the inside of the cats looked great! I probably could have just repaired the hole. Anyway, I installed PPE catted downpipes and replaced all sensors and hardware. Relatively easy replacement with no major issues. No problems since! Thanks for the suggestions!

 

[SeanDev]

The hole appeared to be caused from exterior corrosion on a weld. After removing, the inside of the cats looked great! I probably could have just repaired the hole. Anyway, I installed PPE catted downpipes and replaced all sensors and hardware. Relatively easy replacement with no major issues. No problems since! Thanks for the suggestions!

The PPE are worth it. Did you go with a new tuner? Moving away from LMS will save your transmission.