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My Cat. melted, what to do.

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Old 05-18-2011, 11:59 AM
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My Cat. melted, what to do.

So my Cat. converter has melted and with the CEL on theres no chance to pass inspection. Mazda has quoted me 1300 for a cat and that seems crazy. Ive done a lot of the research on exhaust systems and it seems im better off just getting an aftermarket one. Problems is I know nothing about them.

What do people think is the best option for someone who wants more HP, but isnt looking to make a lot of noise. I dont want anything too loud, but it will need a cat and cant throw the CEL light. I was looking into Borla and B&B but the exhaust thread was very dated and wanted to know if anything better is available.
Old 05-18-2011, 12:29 PM
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how old is your car if is less that 80.000 mile it is cover under warranty!!!
Old 05-18-2011, 12:54 PM
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Originally Posted by sebarx8
how old is your car if is less that 80.000 mile it is cover under warranty!!!
Your making an assumption that the OP is in the U.S.
Old 05-18-2011, 12:58 PM
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More information is need to assist you:

Your location
Year & Mileage of RX8

Also I have an extra catalytic converter sitting in my garage if you what to buy it for less than $1200
Old 05-18-2011, 01:26 PM
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The answer depends a lot on where you are located. If the emissions test is a code readout of the OBDII, then pretty much any cat will work. If they do a sniffer, you might pass. If they look at the cat itself, then you may be hosed, even if it passes the sniffer. Finding a used but functional stock one is a matter of luck.

Here are some options and comments about sound for hi-flow cats: https://www.rx8club.com/showpost.php...0&postcount=23
Old 05-18-2011, 01:49 PM
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Have you tried RockAuto?

I haven't tried the cats they're selling, but my experience with the parts they sell have been really good.

Looks like $265.59 for a Walker cat from RockAuto.
Old 05-18-2011, 05:02 PM
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Walker Exhaust is a pretty well known company that makes direct-fit parts.

I bought their Exhaust for my FC, I would say Quality-wise(welds, constructions,etc ) its nowhere as good as OE (or other more famous 3rd party manufacture), as for durablility its not even installed so I can't comment on that.
Old 05-18-2011, 05:35 PM
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Thanks for that info nycgps.
I think when my cat goes, I'll try it out, if I don't get tempted by a midpipe.
Old 05-19-2011, 03:39 AM
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evilrulz if you add a general location to your user id it would help us to answer your question.
Old 05-19-2011, 11:16 AM
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He's in NH and he's over 80,000 miles.
Old 05-19-2011, 12:36 PM
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Correct, in NH and its now over 80k. The cat actually melted at about 79k but mazda replaced the ignition coils and said the cat was fine, within a week or 2 the CEL came on and showed a cat code. The cat had melted and took both 02 sensors w/ it and the plugs too boot. Since it had crossed 80k Mazda refused to warranty it.

Now its needs to get inspected and im looking for either the cheapest Cat that will work or go with a whole new system if it makes sense.
Old 05-19-2011, 03:15 PM
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Well you could buy a midpipe with some type of high flow cat welded in, BHR does this. You could also check the for sale section and wait for someone to be selling a used oem cat, but I think the BHR one is a better option. As long as a cel does not pop up you should be fine.
Old 05-19-2011, 04:15 PM
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I would contact MNAO and argue that the cat had previously failed and that you were working towards resolving the issue when your mileage rolled over 80K. You took their recommendation in good faith and their fix did not resolve the issue.
Old 05-20-2011, 08:11 AM
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Originally Posted by Evilrulz
Correct, in NH and its now over 80k. The cat actually melted at about 79k but mazda replaced the ignition coils and said the cat was fine, within a week or 2 the CEL came on and showed a cat code. The cat had melted and took both 02 sensors w/ it and the plugs too boot. Since it had crossed 80k Mazda refused to warranty it.

Now its needs to get inspected and im looking for either the cheapest Cat that will work or go with a whole new system if it makes sense.
ahhhhhhhh find a friend under warranty change the cat with him and he can get a new one for you!!!!! good luck
Old 05-21-2011, 08:28 AM
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Originally Posted by Evilrulz
Correct, in NH and its now over 80k. The cat actually melted at about 79k but mazda replaced the ignition coils and said the cat was fine, within a week or 2 the CEL came on and showed a cat code. The cat had melted and took both 02 sensors w/ it and the plugs too boot. Since it had crossed 80k Mazda refused to warranty it.

Now its needs to get inspected and im looking for either the cheapest Cat that will work or go with a whole new system if it makes sense.
I would definitely fight them over that, the cat was bad before the end of the warranty and they know it.
Old 05-21-2011, 10:22 AM
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Originally Posted by Evilrulz
Correct, in NH and its now over 80k. The cat actually melted at about 79k but mazda replaced the ignition coils and said the cat was fine, within a week or 2 the CEL came on and showed a cat code. The cat had melted and took both 02 sensors w/ it and the plugs too boot. Since it had crossed 80k Mazda refused to warranty it.

Now its needs to get inspected and im looking for either the cheapest Cat that will work or go with a whole new system if it makes sense.
if that happens to me I will raise hell at them.

Cuz obviously it's their problem.

I will call Mazda directly and tell them what happen, Mazda gave people free engine replacements even when they're slightly out of warranty, and a CAT is much cheaper than an Engine. Give it a shot.

if all else fails and you really need a CAT, either do what others suggested swap it with some other dude who's still under warranty, buy a high flow CAT and hope it doesn't fail(it did happen), or just get stuff like Walker Exhaust CAT that comes with couple years of warranty(it might fail too, but higher chance to get warranty on that than any high flow cat)

Walker Exhaust has a 30 bux rebate for their Direct-fit cat.

and their warranty is 25K for the CAT material, 50K for the shell and pipe, not for use in California tho.

Walker® Standard Catalytic Converters, available for Pre-OBD (1995 and older) vehicles are engineered with durable stainless steel bodies, OE-style design features, including hangers, flanges, decouplers, and brackets for precision fit. Walker® Catalytic Converters, an industry leader for import and domestic applications, meet EPA emission requirements, and have a 25,000-mile catalytic performance warranty, in addition to a 5-year/50,000-mile structural integrity warranty.
Designed for use on Pre-OBDII vehicles. (1995 and older)
Stainless steel body, heat-shielded pipe and structural brace for enhanced strength and durability.
Meet EPA emission requirements

Last edited by nycgps; 05-21-2011 at 10:27 AM.
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