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Howard
Dodge Dakota
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5/07/2012
11:22:55
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 Subject: Blowin Catalytic Chunks
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Anybody had this happen? Truck died while sitting at a light and acts like it is out of fuel when attempting to restart. Prime the throttle body and it fires but will not stay running longer than a few minutes. After a few restarts and stalls it quits firing completely. Checked for trouble code but the check engine light will not start the test. Pull the coil wire and there is no spark. Replace the coil, turned the key, nothing, battery doesn't have enough juice. Connect jumper cables and the truck fires up but runs very rough then stalls. Try again and it starts but now it is blowing smoke and starts making a noise that sounds like nuts and bolts rattling through the exaust. I shut it down to investigate and HOLY MACKERAL there were actual chunks of that stuff inside the catalytic converter that had been blown out of the exaust. Most of the peices are about the size of pebbles. The largest piece is maybe 1"x 1" and is about 40' from the truck. Towed the truck home, removed the exaust and the muffler sounds like its full of gravel and there is a hole through the stuff inside the converter. What the heck happened that could have caused this? Should I be worried about this or is it normal when the Cat goes bad it breaks apart and starts shooting out of the exaust pipe? Is there a problem somewhere else that I should be addressing prior to putting a new Cat on? What about the muffler? Should it be replaced also?
Details:
1993 Dakota SLT 4X4, 5.2 Litre 318 with 205,000+ California highway miles, Failed most recent smog attempt. Maybe because the catalytic converter was going bad?
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Fred
Dodge Dakota
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5/07/2012
11:26:45
| RE: Blowin Catalytic Chunks
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There might have been a lot of gas in the engine and when you finally got it to start, it heated up the cat to burn off all the excess. Is your alternator ok? if your battery was dead and it only ran for a little bit after jumping it thats a possiblity.
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Howard
Dodge Dakota
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5/07/2012
14:33:54
| RE: Blowin Catalytic Chunks
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Haven't checked the alternator. Wasn't a problem before. I did forget to mention that I checked for trouble codes after changing the coil and 25 was the only code stored. That is the Idle Speed Control (ISC) circuit and this isn't the first time that code has come up. Sometimes the truck will surge up and down while idling but it usually corrects itself once the engine warms up.
What, if anything, does the altinator have to do with the catalytic converter? The battery wasn't completely dead when I jumped it. It turned the motor over but it was real slow.
I figure that the Cat was factory original and they don't last forever, but do they always blow like that when they finally go bad? Won't these trucks run without a Cat, like if you had headers and uncapped them like they do at a 1/4 mile track? I have heard of guys doing this back when I used to go watch the races in Colorado. Of course that was 30 years ago so maybe its not done today. Anyway, I'm definately changing the Cat and probably the muffler to. Hope thats all because those two alone will put a serious crease in the wifes spending habits. Everything happens for a reason and thats a pretty good reason that this happened. That answers her question of "what next"? Its a Dodge thing sweetie, nothing happening only means that something is about to. Thats my story anyway...
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Fred
Dodge Dakota
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5/07/2012
14:40:32
| RE: Blowin Catalytic Chunks
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If too much gas is going into the engine which isnt getting burned, it will soak everything... then once it fires up all that excess gas will burn up in the cat. That might damage it. I never heard of chunks blowing out though.
I had the same trouble with that idle problem espeically when it is humid out. It was the IAC sensor. It wouldn't hold an idle unless I held the pedal down a little until it warmed up. It is like a $20 part and only takes 2 screws to install. I dont know if this is your problem, but it sure is annoying when those things go bad. I think its common too.
Why was your battery dead? from cranking so much or was it dead after some regular driving?
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Howard
Dodge Dakota
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5/07/2012
16:08:57
| RE: Blowin Catalytic Chunks
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The battery was going dead from cranking it too much. It wouldn't start so the guy with me kept trying to prime it by pouring fuel into the throttle body. But since the problem was with the coil not sparking the fuel wasn't going to do anything. By the time I convinced this bonehead to stop "priming it" he had probably poured a dollars worth down the throttle body ports. My fault for hangin out with a dipshtick or letting a dipshtick hang out with me and for not paying attention to what he was doing. Anyway, thats probably the cause for the Cat blowing out. I did hear it backfire when it was trying to stay running just prior to the sound that sounded like nuts and bolts shooting out the exaust pipe. Hope nothing was damaged the other direction, from the Cat to the engine. Thanks for shedding some light on why this took place. I know now what I wish new then. Funny how that works.
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Fred
Dodge Dakota
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5/07/2012
16:14:02
| RE: Blowin Catalytic Chunks
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Yes thats probably it. If all is well except the bucket of bolts sound, then youre probably fine. That sound is normal when the cat is toast. I have gone through many that made that sound. I dont know what your state inspection requirements are for emissions, but other than a little back pressure, that rattling probably isnt going to hurt anything except your ears.
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Howard
Dodge Dakota
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5/07/2012
16:34:49
| RE: Blowin Catalytic Chunks
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It couldn't be driven, it wouldn't stay running. If you were able to drive with a blown cat maybe I have a bigger problem. Like I said I am changing the Cat and probably the muffler to before I attempt to start the truck. Could I start it with just the crossover pipe connected to see if it will run? What do you think is causing the muffler to sound like its full of rocks when I shake it? It's still attached to the tail pipe and hanging under the truck for now so I haven't really checked it out yet.
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daddio
Dodge Dakota
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5/07/2012
19:45:13
| RE: Blowin Catalytic Chunks
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Howard, have you repaired the #115 splice? It is in the harness coming out the bottom of the PDC about 4 to 6 inches down. 3 wires to one, red or red/white. Check it out.
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Mark
Forum Moderator
5/07/2012
20:20:47
| RE: Blowin Catalytic Chunks
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wow What is this splice you speak of for the 1993 V8?
-Mark Hryckiewicz
1993 Sport RC SB 5.2L Auto
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Howard
Dodge Dakota
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5/07/2012
20:46:10
| RE: Blowin Catalytic Chunks
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Daddio,
First, How are ya? It's been awhile but I'm back with yet another problem. Yes, I am aware of the splice but I haven't checked it lately. Usually that is one of the first places I look for a problem. This time the trouble seems to have been the coil since a new one fixed the original problem. Thanks for the reminder and I'm going to take a look at that just to be sure. After all, it is a Dodge.
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Bucket
GenII
5/08/2012
01:24:55
| RE: Blowin Catalytic Chunks
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You might want to hollow out the old cat
first, clean out the muffler and bolt it back
together to see if its gonna run so you
dont ruin a brand new cat if for some
reason you are dumping fuel.
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daddio
Dodge Dakota
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5/08/2012
12:59:09
| RE: Blowin Catalytic Chunks
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Mark, I'm suprised you've never run across the infamour #115 splice. It come sout of the PDC about 4-6 inches in the harness. It is very common for it to corrode and cause all sorts of problems like stalling, no start, etc.. I believe it supplies power to the coil, fuel pump, ASD relay and ignition.
By the way, thanks for chasing out the riff raff.
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Howard
Dodge Dakota
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5/08/2012
13:58:57
| RE: Blowin Catalytic Chunks
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There was "riff raff"? On these boards? But WHY?
OK now I need a new tip. Lets see if I get any responses here or should I open a new thread.
I am having a hell of a time trying to seperate the exhaust pipe from the crossover pipe. It was crimped with the standard type exhaust clamp, which came off without breaking the stud off, and I have been able to work a flat punch around the lip of the pipe to get some space but it just will not seperate. I have even hooked a come-along from the rear axle to the pipe just foreward of the Cat and this thing is seriously stuck. Its not welded at this joint but I worked on the damn thing for a few hours yesterday and I don't see that it has moved at all. The two peices are loose enough to wobble and barely spin a fraction either direction but still stuck. I sure hate to have to cut the pipe and sleeve it somewhere else but I can't see any other option. Anyone have an ancient chinese secret they can share with me? I'd be willing to part with a first born child in exchange for the "easiest" way to get these pipes apart. Only you can't tell the wife about this. OK?? Sacrifices have to be made dammit!!! Now I wait for a response packed with knowledge and wrapped with smarts.
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Fred
Dodge Dakota
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5/08/2012
14:10:00
|  RE: Blowin Catalytic Chunks
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Open a new thread with a new subject. That will help with searches.
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Howard
Dodge Dakota
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5/08/2012
14:16:14
| RE: Blowin Catalytic Chunks
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Alright, thats what I'll do.
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Mark
Forum Moderator
5/09/2012
07:14:13
| RE: Blowin Catalytic Chunks
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Yeah the riff raff turned out to be only two people in california making a complete mess of things. They are blocked now along with a couple spam bots. Sorry for all that.
As for the splice, no I never had that corrode... amazing becuase I have the hood scoops which lets water in a little bit if I'm parked on an incline. I have had the blower resister pack go out a couple times. Its a dealer part but very reasonable. I think they are $12.
-Mark Hryckiewicz
1993 Sport RC SB 5.2L Auto
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