Signs of a Failing Catalytic Converter in the Ford Explorer Sixth Generation (2020-Present)

The catalytic converter is a critical component of the emissions control system in your Ford Explorer. A failing catalytic converter can lead to poor engine performance, increased emissions, and potential damage to other components of the exhaust system. Here are the common symptoms of a failing catalytic converter:

Step 1: Check for Diagnostic Trouble Codes (DTCs)

• Tools Required: OBD-II scanner
• Procedure:
  1. Connect an OBD-II scanner to the vehicle’s OBD-II port (usually located under the dashboard).
  2. Read any stored trouble codes. Look for codes related to the catalytic converter (e.g., P0420, P0430).

Step 2: Inspect Exhaust System

• Tools Required: Flashlight, jack and jack stands (if needed), safety glasses
• Procedure:
  1. Visually inspect the exhaust system for any signs of damage, such as rust, holes, or signs of overheating.
  2. Check the catalytic converter for any signs of physical damage or rattling.

Step 3: Conduct a Back Pressure Test

• Tools Required: Manifold gauge set or a back pressure tester
• Procedure:
  1. With the engine running, install a back pressure tester in the O2 sensor port or upstream of the catalytic converter.
  2. A back pressure reading above 2.5 psi at idle or above 3.0 psi at 2,500 RPM indicates a possible blockage in the catalytic converter.

Step 4: Perform a Temperature Test

• Tools Required: Infrared thermometer
• Procedure:
  1. Measure the temperature of the exhaust gas entering the catalytic converter at the inlet.
  2. Measure the temperature of the gas exiting the catalytic converter at the outlet.
  3. A temperature difference of less than 100°F (38°C) indicates that the catalytic converter may be failing.

Repair Instructions

If you confirm that the catalytic converter is failing, follow these steps to replace it:

Step 1: Gather Tools and Parts

• Tools Required: Wrench set, socket set, ratchet, jack and jack stands, exhaust hanger removal tool, penetrating oil, safety glasses, gloves
• Parts Required: Replacement catalytic converter, exhaust gaskets (if applicable), O2 sensor gasket (if applicable)

Step 2: Raise the Vehicle

1. Park the vehicle on a level surface.
2. Use a jack to lift the vehicle and secure it with jack stands for safety.

Step 3: Remove the Exhaust Components

1. Apply penetrating oil to the exhaust bolts to loosen them.
2. Remove the bolts securing the catalytic converter to the exhaust manifold and the exhaust pipe.
3. If applicable, carefully disconnect the O2 sensors upstream and downstream of the catalytic converter.

Step 4: Replace the Catalytic Converter

1. Position the new catalytic converter in place, ensuring it aligns with the exhaust manifold and exhaust pipe.
2. Reinstall the exhaust bolts and tighten them to the manufacturer's specified torque.
3. Reconnect the O2 sensors if they were removed.

Step 5: Lower the Vehicle and Test

1. Carefully lower the vehicle from the jack stands.
2. Start the engine and check for leaks around the new catalytic converter.
3. Use the OBD-II scanner to clear any stored trouble codes and perform a test drive to ensure the Check Engine Light does not reappear.

Conclusion

A failing catalytic converter in your Ford Explorer Sixth Generation can result in significant performance issues and increased emissions. By following the diagnostic steps outlined above, you can determine if the catalytic converter is the source of the problem. If replacement is necessary, following the repair instructions will help you safely and effectively replace the component. Always consult the vehicle's service manual for specific torque specifications and procedures.