Mechanics

WHAT IS CAUSING CATALYTIC CONVERTERS TO CLOG?

2004 Ford Escape • 6 cylinder 4WD Automatic • 95,000 miles

2004 Ford Escape XLT, 3.0L V6, 98,000 miles.

4,000 miles ago, I had a new rear catalytic converter put on my Escape b/c it had become clogged.

I recently replaced all six plugs and coils b/c a few cylinders were misfiring. After doing that, I was soon was getting engine codes from two O2 sensors for 'lean' gas. So I checked for vacuum leaks, verified all hoses and connections were ok, the manifold bolts were torqued correctly, and I could not find any leaks. I replaced the PCV valve (the old one barely rattled anymore)so I am hoping I fixed the 'lean' engine code issue.

Now, the same converter is clogged again after only 4,000 miles. My questions.

Did the converter possibly become clogged b/c of the cylinder misfires and 'lean' gas issue?
Are there other underlying issues I could check out that may be causing the converters to fail?
I am not sure if I have solved the problem with new plugs, coils and a PCV valve, or if there is something else going on that will destroy another converter.

Thanks to anyone in advance for your expert advice.
Avatar
Leodajim
March 28, 2011.



Update to above.
The muffler shop tells me that the catalyst in the converter actually melted down and broke apart. From my limited knowledge, I think that means my engine is running too rich. Again, I don't know if I have already fixed the issue by replacing coils, plugs, and the PCV valve. I don't know what other things to check and/or tests to perfrom to make sure there is still not an issue with the engine, thus ruining another converter. Any expert advice is much appreciated.

Tiny
Leodajim
Mar 28, 2011.