Any one seen this from a plugged up catalytic converter?
2002 F150 lariat 193,000 miles. I changed all plugs and coils and ran out of ideas until it really started to run rough. looked for a vacuum leak and found the melted manifold... any suggestions would be great.




My mechanic friend said the exhaust that is recirculated was so hot that it melted the intake. Makes sense to me but wanted to ask.





This is the front driver side where I had one of the High Temp Emissions Hoses came off (thought that it was just old) and melted a hole and a groove. I put some plastic epoxy on it and guess what it didn't make a difference.

 

It is a Dorman, correct?
Could be less temp resistant than the ford or something? No idea. Never seen it either.

 

Sounds plausible to me. I can't say that I have much faith in your epoxy repair though.

 

It sounds like EGR problem holding heat in the intake. I've never seen this, but I've been around some BBF at the EGR and it would of melted a composite intake. It did melt the choke housing cover and carb cam. That tells you how hot that must of been.

 

Didn't think about EGR.... good call AK

 

@ white-- I didn't have much faith in the epoxy job either, I was just looking to narrow down my search. It is still holding on tight, surprising.
@ AK I will try to check the EGR out tomorrow.

 

So it was the Catalytic converter after all. EGR checked out OK. I loosened up the exhaust from the manifold and it ran much better. Thanks for the help, I wish it would have been the EGR! I didn't post the problems that it was having-- no power, idle would vary by 800 rpms, felt like 4 cylinders were missing.....

 

Glad you were able to get to the bottom of the issue, Birley. If you need a replacement for the bad catalytic converter, we have a few options that are more affordable than an OE unit. Let us know if we can help at all!