OEM 2004 Dodge Durango Catalytic Converter

2004 Dodge Durango Catalytic Converter Parts and Q&A

• Q: How to Safely Remove and Install a Catalytic Converter on 2004 Dodge Durango?

  A: Before removing the catalytic converter, lift and support the car, then soak all exhaust bolts and nuts with leopard Rust Penetrant and wait 5 minutes. Untie the oxygen sensor connectors, followed by removing the bolts that hold the catalytic converter to the manifold (5) and remove the clamp that attaches the catalytic converter to the exhaust pipe(s) (1). If you see tack welds, grind them, then remove the clamp holding the flange to the muffler or pipe extension before you can remove the catalytic converter. During an inspection, make sure the converter's stainless steel body does not show signs of bowing or distortion from excessive heat and that any attached heat shield is neither bent nor loose. Sometimes, if you suspect the catalyst has internal damage, hitting the bottom with a rubber mallet can show if the core is damaged. Ensure there are no burrs on the catalytic converter pipe, place the converter into the exhaust pipe until it sits right and ensure the alignment tang is seated all the way down in the right slot. If you noticed other loose areas during the removal process, use the correct steps to secure them back. Put the clamp and nuts onto the system at the catalytic converter-to-extension pipe joint and tighten them to a torque of 41 Newton meters (about 30 foot pounds). Once your car is set at the lower level, turn on the engine and look for exhaust leaks, then take care of any repairs or adjustments on the exhaust and put some space between the pipes and the panels.