[Infidel]

I ordered Magnaflow Direct-Fit, High flow CAT with Pipes. I bought from AutoAnything.com, priced at $285.42. I found a discount code online and got 15 bucks off. So including shipping from Californina to South Carolina, I paid $270.42. Not bad, I think. The nice thing about ordering parts is the time you have to prep and plan. While waiting for the CAT to arrive, I was spraying the exhaust bolts daily with PB Blaster. The other day, I broke the nuts loose and purchased my gaskets at Advance Auto Parts. I was worried that the nuts would be BEARS to remove, but it's really an easier project than changing plugs. I did have a friend helping me, but the entire project took a little over an hour. (would have been quicker if another trip to Advance was not required - I'll get into that later) I had no problem getting access to the nuts with a large assortment of 3/8" wobble extensions.

Once all the bolts were off, I braced the transmission with a jackstand. I dropped the steel cross member, pipe hanger bracket (Probably unnecessary) and disconnected the 3 o2 sensor harnesses. At this point, it popped right out with no problem. We compared the old cat to the new and saw that the Magnaflow had 4 holes for o2 sensors and my van has only 3. I was not expecting this, but figured for now, we could buy an OLD Ford sparkplug to fill the gap. Thus, the trip to the parts store. (any suggestions for a nicer fix?)

We set the new gaskets and the new CAT fit perfectly. We bolted everything up and plugged it all back in.

When finished, I cranked it up and checked for leaks- All good! I found this to be a VERY EASY install. Probably easier because of a weeks worth of spraying with PB Blaster on the nuts. I have been driving my Astro with a hollow converter for a few months. The new High-flow converter eliminated the "airy" sound that I was getting. I am surprised though that the sound is actually a bit "throaty" with the stock exhaust. Especially in revs and acceleration- cool! I can definitely feel a huge improvement. (Duh! - Hollow converter) Can't wait to start on my CAT back.

 

[astro355]

PB blaster for the win!

Good write up and did you get any pics of the parking lot? :mrgreen:

 

[rev_les]

ehh, take the old ford sparkplug to Lowes or Homie Depot and see if they have a pipe plug with the same threads.I had a set of headers on a car that had O2 sensor bungs built in, and they came with a plug in them if you didn't need O2's, so SOMEWHERE, you should be able to find something. Nice job!!
Now it makes me want to get off my arse and replace the hollow cat on the '99..........well, maybe soon, lol, it's been this way for 3 years, I was finally ready to do it, then I bought the red monster,and it ended up with my Magnaflow.

 

[ritous1]

yep, had the same issue with the 4th o2 sensor hole on mine as well. I got an o2 sensor plug (basically a short bolt with the proper thread pattern) for $5 from the local meineke. They can be found all over ebay as well.

 

[astro355]

Why would you plug the other 02 sensor bung? Why not put the o2 sensor back in it? I guess I'm a little curious about this. The 96 I'm working on right now has 4 o2 sensors, did they eliminate one in 98?

 

[Infidel]

Thanks for the "Bunghole" advice everyone. "Hey Beavis, he said BUNGHOLE"

Good write up and did you get any pics of the parking lot?

No, but the gravel is etched into my back.

Why would you plug the other 02 sensor bung? Why not put the o2 sensor back in it? I guess I'm a little curious about this. The 96 I'm working on right now has 4 o2 sensors, did they eliminate one in 98?

Dunno why, but only has three. Good Lord! Three is plenty!

I forgot to mention that the Magnaflow CAT fit closer to the frame than the stock cat. Seems like it will give better clearance to anyone who may be lowering.

I was planning on being a grown-up and getting my body kit next. That way, I could tailor the exhaust to the body kit. (Dual, rear exit, side swept, etc.) But now the kid in me is wanting to get ANY high-flow muffler on. I like the Gibson that many are installing. Seems like a nice "bolt-on" that I could do myself but I am finding these for around $380. Seems a little steep. Also considering having a "3-in-3" out" Magnaflow XL Turbo installed by a shop. I have been reading that they both have great tones, but the Magnaflow sounds a bit "nastier". (which I like) I wonder how much I could have this done for.

 

[Jasen]

That went a lot easier then my CAT replacement, but I didn't have to $ for the direct fit.

 

[Mr_Bowtie]

Good pics! Definatly get a good muffler to go with the new cat.

 

[rev_les]

It only took me a couple hours to weld in the cat on the '95, I suppose having airtools,a mig and a sawzall might have contributed to that though. :mrgreen:
btw, my '99 only has 3 O2's as well