Catalytic Converters

G-Man · 12-12-2011, 02:54 PM

Hey everyone, I'm new here.

I have owned my 2002 Insight for about eight years. For almost two years our catalytic converter has rattled. It has rattled that long because Honda quoted me $4,500.00 for the parts alone to replace just the cats

not including labor. Heck, that's more than the car is worth!

I just jumped online to search out a few things, found universal cats for around $100 each and then called a muffler shop who could get them and install them for $600.00.

The prices are all over the board. Where have you guys gone and what parts did you use?

**jeff652** · 12-12-2011, 03:11 PM

Make sure it's not the $25 flex/doughnut gasket that goes between the two cats. Aparently those rot out pretty easy and cause a healthy rattle (not that I would know as I live in CA

)

retepsnikrep · 12-13-2011, 12:26 AM

cat heat shield loose, costs $1.00 to fix with a stainless steel hose clamp

Need4Speed · 12-13-2011, 06:29 AM

Like already posted, check the heat shield. I think its two large stainless steel hose clamps to fix the rattle. The rattle is anoying as anything. 10 Chicago salty road winters did it to mine.

samwichse · 12-13-2011, 08:23 AM

Check the gasket that Jeff was talking about. Fixed mine, and was totally invisible, but made the car oh so smooth and silent.

Sam

G-Man · 12-13-2011, 03:41 PM

Will the gasket being loose cause the check engine light to come on?

Willie Williford · 12-13-2011, 07:24 PM

In theory....It could, but the gasket would probably have to be nearly "gone" for that to happen.
Do you have a MIL?

Willie

porshuh · 12-13-2011, 08:11 PM

Does anyone know the bolt/nut sizes for the upper cat heat shield? I tried to take my heat shield off today (need to remove both cats to get them rebuilt), and for the life of me couldn't find a socket that would fit snuggly.

Not to threadjack - but has anyone dropped their whole exhaust out (from exhaust manifold to the muffler)? Any comments on how hard it is?

If you have a loaner car you can use, you can drop the exhaust, and send the problematic cat(s) to be rebuilt. I have heard that is the cheapest solution, as the "generic" ones you find online are not adequate substitutions for the OEM ones.

I plan to attempt to drop the exhaust out with the car in my garage using jackstands. I hope it's not a total PITA. I need to get both cats rebuilt (or gutted

)

**jeff652** · 12-13-2011, 08:18 PM

ALL of the cat heat shield bolts are 10mm. I removed all of them a few weeks ago from the 2004 Insight that I am stripping down for parts.

Removing the exhaust system is relatively easy. The first cat clearances are a little tight. Be careful not to break the spring bolts that hold the 1st and 2nd cat together (where that doughnut gasket is). They can get rusted and brittle. Use lots of liquid wrench and heat if necessary. I had one snap on the 2004 and it was a PITA to work it off without damaging the flange on the cat.

Depending on how rusted things are, It can be as little as 30 minutes to remove the entire exhaust system.

[shameless plug] I have my pair of 2001 cats for sale if you want to go that route

PM if interested

Need4Speed · 12-13-2011, 09:23 PM

Jeff652 has another post where he has pictures of the complete exhaust.

2001 vs 2004 exhaust comparison - PICS