Catalytic converters are designed to reduce harmful emissions and are often expected to last the life of a vehicle. However, when catalytic converter failure occurs, it can potentially be a problem or malfunction occurring somewhere in the engine or engine management system upstream of the catalytic converter and not a defect of the converter itself. Understanding what causes catalytic converters to fail, and how proper design helps withstand all conditions, is important to preventing repeat failures and to keep the check engine light off.
Why Do Catalytic Converters Fail?
A catalytic converter will rarely fail without a problem occurring elsewhere in the vehicle. Excess heat, contamination, or stress caused by engine or exhaust system malfunctions are the most common causes of catalytic converter damage. Replacing a failed converter without diagnosing the root cause can result in failures and continued emissions issues.
Common converter-related failures include:
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Faulty spark plugs or plug wires
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Incorrect ignition timing or improper fuel mixture
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Malfunctioning check valves
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Damage or leaks in the exhaust system
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Oil, antifreeze, or excess fuel entering the exhaust stream
- Malfunctioning sensors
Correcting these issues is essential to prevent catalytic converter damage from reoccurring. These failure types are not covered under warranty.
Common Types of Catalytic Converter Damage
When engine conditions are not properly controlled, several types of catalytic converter failure may occur. Catalytic converter failures caused by these conditions are not covered under warranty, as they result from engine or exhaust system malfunctions rather than the converter itself. Issues include:
|
Catalyst Meltdown |
Carbon Deposits |
Catalyst Fracture |
Overheating |
|---|---|---|---|
| Super-heated due to raw fuel in the exhaust flow, which can cause engine damage. | Oil, antifreeze, or too-rich fuel mixture entering the exhaust. Heat-related engine problems may occur. | Ceramic substrate becomes loose, cracked, and begins to break (often caused by physical damage). Partial meltdown may occur. | Glowing red/discolored indicates catalyst meltdown, which can damage engine. |
A catalytic converter will rarely fail without a problem or malfunction occurring somewhere in the engine or engine management system upstream of the converter. It is important to determine the cause of the failure and repair it in order to prevent a reoccurrence.
How Is MagnaFlow Different?
Our catalytic converters combine efficient design and state-of-the-art manufacturing to create a product that meets or exceeds the highest required emission standards in the industry. MagnaFlow offers two kinds of substrates for our catalytic converter line: metallic substrate catalytic converters, often featuring lower cell densities, such as 200 cells per inch (CPI), and ceramic substrate catalytic converters, which may use higher cell densities up to 600 CPI.
Through our state-of-the-art research & development, MagnaFlow is able to design, manufacture, coat and test our catalysts in-house to exceed CARB and EPA standards, ensuring low emissions compliance. MagnaFlow exceeds the industry standard through:
3D Laser Scan & Modeling
OEM components are digitally scanned to create precise CAD models with key design features critical to proper functionality and efficiency. These scans capture millions of data points accurate to thousandths of an inch. |
Validation & Testing
CAD models are used to validate fitment and manufacturing processes to support 100% fixture-built finished goods. Every new part undergoes 5-gas in-house emissions testing to meet stringent quality and performance standards. |
Industry-Leading Application Coverage
Extensive coverage for both CARB-regulated states (CA, CO, NY, ME) and Federal-regulated states helps ensure emissions compliance no matter where your vehicle is registered. |
Premium Construction
High-quality stainless-steel construction delivers corrosion resistance, long-term durability, and a clean, long-lasting finish built for real-world driving conditions. |
Dependable Performance
MagnaFlow catalytic converters are backed by a trusted 5-year/50,000-mile construction warranty, offering confidence in performance, fitment, and reliability. |
Always In Stock
MagnaFlow catalytic converters are available with same-day expedited shipping nationwide, helping you get back on the road faster. |
By combining our research and development, MagnaFlow helps ensure consistent catalytic converter performance. So, no matter what you drive, we make sure you can have the confidence in making the right choice for your vehicle.
