Some welding content...Got a sort of free 2003 V6 Ford Escape a few months ago. Front brakes were shot and I needed a 20 tons on the press to remove one of the front rotors from the hub...major rust between the OD of the hub and the ID of the rotor hat. Bearings in hubs were shot anyway, so replaced them also. Car has three catalytic converters. It appears the underbody cat was replaced at some point with aftermarket part that sort of fit...probably melted due to a failed coil pack...Major exhaust leak on the rear bank manifold cat...can was cracked in two places. Had to pull intake manifold, wiring harness, alternator, under pan, etc. etc to remove. The substrate looked fine, so I TIG welded up the can with some Inconel wire and reinstalled. Before putting back the Y pipe, I put a borescope up the outlet of the front manifold cat..and guess what... the substrate in the front manifold cat is totally gone. It seems that there are no aftermarket front manifold cats made for this car, so I may have to shell out 500+ bucks to the Ford stealer. Just out of the 80K mile emission warranty too. Local junkyards, (not in CA by the way), tell me they are not allowed by law to sell perfectly good used units....they must be scrapped! I'm really pissed! Car is running fine now, but is setting a code for the front bank cat, and won't pass inspection next month....arghh.
14 years ago