The failure of a catalytic converter typically happens for one of four reasons.
The first is overheating. This results when fuel gets into the converter, usually from misfiring spark plugs, and burns out the mechanisms inside. Catalytic converters are not designed to handle the heat of burning fuel; when fuel starts to burn in the converter, it can cause a great deal of damage to the converter and the rest of the exhaust system. One of the noticeable symptoms of overheating in the converter is a significant loss of power from the engine.
Another converter failure is a contamination of the chemical mechanisms. In some cases, motor oil or antifreeze can find their way into a catalytic converter and prevent the converter from being able to perform its chemical reactions. A common symptom of this kind of failure is a raised level of emissions that could reach the point of being illegal.
A hot catalytic converter needs to cool down before it can be exposed to a cooling agent such as cold rain or snow. If a hot converter is hit by snow, ice or cold rain, this could crack the shell of the converter and begin to cause a rattling sound.
The final type of failure is simply running over a rock and having it impact the converter, or any other type of physical damage that could occur during the course of driving. Depending on where the converter is damaged, one of the symptoms of physical damage could be raised emissions or a drop in engine performance.
Effects
•There are many signs that the catalytic converter may be in need of service, but two of the more common signs are engine performance and an odor associated with a failing converter.
A converter that is damaged can cause the engine to not function properly. For example, the engine struggles when going up inclines, it hesitates when you try to accelerate or you experience a noticeable drop in fuel economy. If a tank of gas is not taking you as far as it used to, then it may be time to have the catalytic converter looked at.
An imbalance in the air-to-fuel ratio can cause excessive amounts of sulfur to be burned during the converter's operation. This can result in a distinctive "rotten egg" smell that is often associated with burning sulfur. Do not ignore that burning smell if you experience it while driving your vehicle--it could be your catalytic converter in need of repair.
Significance
•A catalytic converter that shows any symptoms of failure will need to be replaced. In most cases, a catalytic converter cannot be repaired because it is an enclosed system that cannot be opened to be repaired, much like a battery cannot be opened and repaired because the battery is a closed system using chemical reactions to operate. Replacing the converter should not be the end of the repair job. To make sure the new converter is not damaged, you should find the cause of the defect and repair it. It could be a faulty computerized sensor causing the problem, a damaged cylinder in the motor or bad wiring to the spark plugs. If the source of the problem is not solved, then the new converter will meet the same fate as the old one.
Warranties
•Most catalytic converters installed on new vehicles are designed to last well beyond the 100,000-mile replacement threshold of most new car warranties. If you find that your catalytic converter is damaged before 100,000 miles, it never hurts to check and see if you qualify for a free replacement converter from the car manufacturer.
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Originally Posted by Dorny1
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