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Catalytic converter technology has advanced in recent years. Here, an OE '80s-vintage pellet-style unit (top) will be replaced by a more-compact "honeycomb" converter. Identical overall length and pipe size makes this a direct replacement.
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Begin by spraying penetrating lubricant on the clamps. This car's original cat-to-muffler intermediate pipe was previously replaced (and welded on) or this job would conceivably be a dual-clamp no-brainer.
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Loosen the clamp(s).
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Because the downstream connection was welded, cutting was necessary.
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Remove the old converter. It might need to be hammered free. If so, be careful not to disturb other joints and connections in the exhaust system.
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Insert the new converter, using a dead-blow hammer if necessary.
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A patch piece was clamped into place to bridge the gap where the old pipe was cut. In this case, the exhaust still leaked at the patch, so we welded around the circumference of both downstream joints. Access can be tight; weld at your own risk, avoiding wires and fuel lines.
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