Hey all: I'm wondering if anyone has purchased one of these Magnaflow "direct fit" catalytic converters recently for their California FJ60. I received one today and it looks like it will bolt into the exhaust pipes OK, but my catalytic converter temperature sensor bottoms out on a mesh screen before it is fully inserted. Has anyone had this experience? what did you do about it? Thanks!
Magnaflow CARB Catalytic Converter 3391894
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fjc-man
SILVER Star
I have a 79 FJ40 with a magnaflow cat, I bet if not the same is real close. I had the same issue you are with the temp sensor. I had a piece of brass laying around with a convex shaped end that I used as a spacer.
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- #3
Thanks for the pics FJC-man. Yours looks like the old one I am replacing. IIRC, on my old one, the tube was too long so I cut it down and flared it. I may have to come up with a spacer for this new one...
I called Magnaflow and their support person told me to use the bolts to pull the flange faces together. I told him there was about a 1" gap (similar to your's I think). My sensor is actually hitting the honeycomb and there is no way that forcing it will do anything except damage the honeycomb or the sensor, or both. Now I have a suspicion that the honeycomb is installed in the wrong place inside the housing...I also noticed that there is weld spatter on the honeycomb at the inlet side. It looks like it is from welding in the tube for the sensor. I paid $1400 (with CA state tax) for this thing and I'm not too happy about having to force or adapt anything...
I called Magnaflow and their support person told me to use the bolts to pull the flange faces together. I told him there was about a 1" gap (similar to your's I think). My sensor is actually hitting the honeycomb and there is no way that forcing it will do anything except damage the honeycomb or the sensor, or both. Now I have a suspicion that the honeycomb is installed in the wrong place inside the housing...I also noticed that there is weld spatter on the honeycomb at the inlet side. It looks like it is from welding in the tube for the sensor. I paid $1400 (with CA state tax) for this thing and I'm not too happy about having to force or adapt anything...
fjc-man
SILVER Star
I spaced it so it doesn’t touch the honeycomb. I wouldn’t go along with the idea of forcing either. So the back story reason for the temp probe is, should the cat overheat the emissions control unit would disable air injection.
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- #6
Yeah, I agree the temperature sensor doesn’t do much but I think it is needed for the visual inspection.
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- #7
I'm working with another customer service person at Magnaflow. I sent them some pictures so I'll post them here. It seems to me that the honeycomb core is installed too close to the side where the thermosensor port is (exhaust outlet). But I have to convince them of that...
The discoloration of the honeycomb core looks like it is weld spatter from welding on the thermosensor port. The discoloration was there when I opened the box...
The discoloration of the honeycomb core looks like it is weld spatter from welding on the thermosensor port. The discoloration was there when I opened the box...
fjc-man
SILVER Star
mbb, make a spacer and use 6mm locknuts on the longer bolts and you’ll be home “free”.
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I guess I'm making a spacer...or trying to source a shorter probe, but I think the spacer solution will be easier. I did hear back from Magnaflow, the vendor. This is their response:
"Thank you for allowing us sometime, to do some research on the concern you're having. In doing our research, it is unfortunate that, this part will not be compatible for your vehicle application. There was a change in the temperature probe size, that happened from 1981 onward. The two parts we offer, the direct fit and universal will be for the smaller temperature probe. Please take this case#316574 to the retailer you purchased from, to get a refund."
I did look up some parts, and there was a part number change for the FJ60, but this happened in 04/1985, not 1981. I also looked up part numbers for the 1980-1983 FJ40s and they all have the same part number but different from the two identified for the FJ60. If anyone knows of a shorter temperature sensor probe, I would like that information...
Thanks.
"Thank you for allowing us sometime, to do some research on the concern you're having. In doing our research, it is unfortunate that, this part will not be compatible for your vehicle application. There was a change in the temperature probe size, that happened from 1981 onward. The two parts we offer, the direct fit and universal will be for the smaller temperature probe. Please take this case#316574 to the retailer you purchased from, to get a refund."
I did look up some parts, and there was a part number change for the FJ60, but this happened in 04/1985, not 1981. I also looked up part numbers for the 1980-1983 FJ40s and they all have the same part number but different from the two identified for the FJ60. If anyone knows of a shorter temperature sensor probe, I would like that information...
Thanks.
fjc-man
SILVER Star
I think making a spacer is your best bet. These temperature probes are like hens teeth anymore, elusive.
fjc-man
SILVER Star
They’re not a available anymore.
Smells like BS to me- Over the years, I've had a dozen or more of those 'Exhaust Gas Temp Probes' in my hands and they've all been the same. But there is a significant parts number change at the usual 5/85 model year, so I suppose it's possible, but the CAT itself is the same 81-87, with only an 1 digit supersession so who knows.
For $1400 stinking dollars you'd think they'd make it applicable for all years.
Seems to me like Magnaflow is NOT making these CARB cert CATs OBD II compliant ? As they are required, by Kalifornia Nutzi Law, to do... ?
Space it and forget it - I've never had any of the biggest PITA smog techs ever say anything about that sensor, even if it was missing.
For $1400 stinking dollars you'd think they'd make it applicable for all years.
Seems to me like Magnaflow is NOT making these CARB cert CATs OBD II compliant ? As they are required, by Kalifornia Nutzi Law, to do... ?
Space it and forget it - I've never had any of the biggest PITA smog techs ever say anything about that sensor, even if it was missing.
Did you end up going the spacer route? I'm in the same boat as you with a 1985 in California and looking at Cat options. I don't want to spend the $1.4k on the bolt in one, especially if theres an annoying workaround with the spacer.
Did you look at the universal weld-in ones? Get any labor priced out and then decide to go with the bolt in?
This AP cat says it fits my FJ60 (per Autozone autofit, which I'm not sure I trust) and is only $430... can't be too much more than $100 to have a muffler shop weld it in. Anyone have thoughts?
DFXR
SILVER Star
Yes, probably $100-ish to cut and weld in place at an exhaust shop. It’s a ten-minute job. I think I paid $60 ten years ago.
BUT, you need to make sure that the AP cat you linked to has the inlet for the temperature sensor. Hard to tell from the photo.
sd60
SILVER Star
i just used some longer bolts and washers w a gasket. 7 years later and it's still working fine. details below
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The Magnaflow cat has a port in the right place for the thermosensor, but the mounting bracket on the thermosensor ends up farther away from the cat, so you'll need longer bolts. I used M6-45 bolts. I was a little nervous about hot air blasting out of the port around the sensor, so I used one of the sensor gaskets from SOR (part 11K in this diagram Page 046 Land Cruiser Exhaust Systems FJ60, FJ62, FJ80, FZJ80 & UZJ100), a smaller washer (1/4" ID), and a larger washer (1/4 "ID) to make sure the port was sealed up nice and tight. The washers are secured on the sensor side by the flange created where the sensor gets thicker, and the gasket fits perfectly in the outside lip of the port. I bought the bolts/nuts/gaskets from SOR - just follow this diagram: Page 046 Land Cruiser Exhaust Systems FJ60, FJ62, FJ80, FZJ80 & UZJ100.
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The Magnaflow cat has a port in the right place for the thermosensor, but the mounting bracket on the thermosensor ends up farther away from the cat, so you'll need longer bolts. I used M6-45 bolts. I was a little nervous about hot air blasting out of the port around the sensor, so I used one of the sensor gaskets from SOR (part 11K in this diagram Page 046 Land Cruiser Exhaust Systems FJ60, FJ62, FJ80, FZJ80 & UZJ100), a smaller washer (1/4" ID), and a larger washer (1/4 "ID) to make sure the port was sealed up nice and tight. The washers are secured on the sensor side by the flange created where the sensor gets thicker, and the gasket fits perfectly in the outside lip of the port. I bought the bolts/nuts/gaskets from SOR - just follow this diagram: Page 046 Land Cruiser Exhaust Systems FJ60, FJ62, FJ80, FZJ80 & UZJ100.
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- #18
Yes I did fabricate a spacer. I'll get some pictures and post up what I did. This new Cat did get me passing results at the smog check station but it is disappointing that the "direct fit" and expensive cat didn't really fit...
DFXR
SILVER Star
I just can't believe that ten years ago I bought a CARB-compliant Magnaflow Cat, with the correct input for the thermosensor, for $187. And at the time I was annoyed because the 49-state version was something like $50 cheaper.
Yup. Now it's something on the order of $1000 difference. And the only difference between the 48-State CATs and the CARB cert ones is a little spot-welded on sheet metal plate that has Newsom's face laser-etched on it.
