Advise? Defective Aftermarket 3VZ-E Cat Conv. w/ only 8k mi..

[NorCalBorn]

Input and feedback here is appreciated, as I hope to figure out why this happened as everything else is in great running condition. Hopefully I have simplified my issue here and worded it good enough.

OK, this is on my 4Runner, the headers are Thorley ceramics, DynoMax 2" inlet/outlet catalytic converter, into a Flowmaster single in/out with 2.25" tailpipe.

My first indication was a little snap/ping/bang sound while driving today. I parked it, let things cool down, and went around the system with a small rubber mallet to isolate the rattle/ping I was now hearing from my exhaust. It literally sounded like a bunch of Cv bearings bouncing around. I then dropped the converter to find the primary honeycomb (there are two in the thing) cracked into pieces.

For reference: *Notice the Converter's Heat Cured Stainless, purplish-red and yellow, the rear's still that color, only the front section is blued out. The HoneyCombs are each located where the raised ribs are in the pic..air gap's probably about an inch or so between them.

No scorching, no clogs visible, just the first honeycomb cracked apart and the metal around it all blued up now. *I did find a small piece of the old exhaust donut in with the stuff, could it have been sitting there, resting just in front of the primary honeycomb glowing really hot and caused enough of a hot spot to crack the ceramic? The weather was around 50 degrees this morning and it happened shortly after warm up.

My plan is to take it down tomorrow and get a warranty part.

Honestly though, it makes me question DynoMax quality and just think I should have gone with the MagnaFlow California Carb legal one instead.

*Maybe this is partially why California pushed for the new legislation? I'm hearing of a couple other people having problems with these Dynomax catalytic converter system parts.

 

[toojayzee]

Are you sure there isnt a reason this occured other than manuf flaw ?

 

[NorCalBorn]

No lean or rich condition, no CEL's at all, at any point. No codes beforehand either, although I'm sure it'll pop a code tomorrow when I have to drive it to get the replacement as it's not gonna be scrubbing as well.

Other than a possible flaw with the converter and the fact the installer re-used the original front donut, that went bad and was replaced (why there was a piece of that in with the cracked ceramic) I cannot identify anything else odd. After we did the head gaskets and tune up it's driven just fine until this happened.

It's just frustrating, you know, the converter's a 04/09 manufactured unit, hopefully it's just a fluke since the newer CA converters have to meet higher guidelines and inspections.

FWIW it did rattle a slight bit when new, maybe the front honeycomb wasn't sandwiched right to begin with or it could have been dropped at some point in shipping/transit, who knows.

Now I'm gonna be pissed off about this until it's fixed, and then it'll be in the back of my mind every time we go long distance over the next 10k miles.

 

[NorCalBorn]

Anyone know the range allowed on the emissions in California for a 1995 4Runner, 3VZ-E, Auto and 5-speed (*if they're different at all?) so I can figure this out? I can't find my info from the manual right now.

Here's where I am at, swapped out the cat for a new one, had it sniffed, and it's passing.

I want to know the range b/c I'm gonna check the operation of the primary O2 sensor, likely because it might be a bit "Lazy" and then re-sniff it.

HC??

NOx??

CO??

 

[NorCalBorn]

Are you sure there isnt a reason this occured other than manuf flaw ?

Aiight, here is the test with just a warranty catalytic converter..pretty good and passing the sniffer, but I found the O2 sensor was acting "lazy".

Now, here is today's test with the sniffer and the dyno, CA smog demons eat this!!
*Not too shabby for a 15 year old vehicle that's underpowered and slightly modded w/ smog legal high flow exhaust, huh?