Has Anyone Ever Plugged Up A Catalytic Convertor While Driving?

Powelligator

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Folks,

Out here in the Denver area we’ve been having a heat wave of sorts, temps just under 100 degrees which for us, even in the summer, is hotter than normal. I say this because it might be a clue to something I experienced yesterday in my ’06 LJ.

Randomly, and concurrent with the hot weather, well after the engine has warmed up, the Jeep has shown me the Yellow Engine Icon of Hell on the dash and since I have a scan gauge hooked up at all times it’s a P0421.

From our friends at Google: The P0421 code on a Jeep means "Warm Up Catalyst Efficiency Below Threshold (Bank 1)." It triggers when the vehicle’s computer detects that the catalytic converter on the passenger side is not cleaning exhaust emissions effectively, usually during the first few minutes of a cold start.

Well this is weird because I’m getting this code well after the Jeep is warmed up, never when it’s cold.

Here’s where things got interesting… Yesterday after work I’m driving along on the freeway, 6th gear, everything’s fine. The top was down and I did not have the A/C on. Suddenly the engine just started to run sluggish. The more I pressed on the accelerator the less it had an effect, I moved over to the right lane and the Jeep is really slowing down, but no mechanical sounds of like rod knock or anything, it just ran really poorly and had zero power. No CEL either. I pulled over onto the shoulder. At this point the engine idled just fine, but wouldn’t rev at all past idle. I got out and checked for leaks, the engine was hot (about 225 degrees) (did I mention the outside air was almost 100 degrees?) so there was gurgling in the radiator and the catch bottle, but no fluid leaks at all. No oil, no connecting rods poking out the side of the block, nothing.

Since I remembered I had those random P0421 codes that pointed to the cat cons I walked around to the back and put my hand to the exhaust. Almost no air coming out - not the normal puff puff puff that it makes and then I realized that the exhaust was quiet. I have a 4.6 stroker and 2 1/2 inch pipe all the way to the back, so it’s always made a rumble, but nothing. I honestly think I have a plugged up cat con.

I walked down the freeway to the next exit, called an Uuuuber for a ride home, got my truck and came back and flat towed it home. Of course by the time I unhooked to put it in the garage, the engine was seemingly OK, still doesn’t want to rev very high and almost no air coming out the exhaust. A quick bit about the history of my cat cons - three years ago I had some serious engine problems and the Jeep was running so rich fuel was just pouring into the cylinders and the crankcase, long story short the drift pin on the bottom of my OPDA came out, the gear on the cam bounced around, the timing went way off and the engine seized. I put in a new engine but never changed out the cats, because looking into them they looked OK.

Question: Has anyone ever experienced this? Is that typical behavior if you plug up a cat con? I only really made it a half mile in its running rough state, can that damage an engine?

Thanks!
 
I had a cat fail driving home to Minnesota from Moab. We were in mid Nebraska.

Sunday afternoon so I didn't have many options.

I was able to reset the CEL and drive 55 mph without issue, anything above that and the load on the engine would trip a random misfire CEL.

Got it home swapped in new cats and it's been fine ever since.
 
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Yes, I had a cat plug up while driving ('97 Dodge Dakota). I managed to drive it home, made a warranty appointment, and drove it, very slowly because it was barely running, to the dealer. By the time I got there, the hot back pressure had warped the exhaust manifolds so badly that they pulled away from the heads, breaking a couple of bolt heads off. If I banged on the cat it rattled like the honeycomb was all broken up.

I would not drive your TJ with a plugged cat.

From our friends at Google: The P0421 code on a Jeep means "Warm Up Catalyst Efficiency Below Threshold (Bank 1)." It triggers when the vehicle’s computer detects that the catalytic converter on the passenger side is not cleaning exhaust emissions effectively, usually during the first few minutes of a cold start.

That's for a JK. The TJ PCM can't detect anything about the third cat directly (passenger side except for Brits and Aussies). But it might see the back pressure and heat at the downstream oxygen sensors, and throw that code.

I would check all 3 cats.
 
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I should probably clarify the above: Yesterday the Jeep went from 70 MPH in the left lane to stumbling with no power with me signaling right and bailing onto the right shoulder in maybe a mile. After about a half hour of cooling things down I was able to limp it maybe another 1/2 mile to the next exit and I shut it down again. I got home via Uuuber, came back with my truck and towed it home. I have no intention on driving it in this state.

I kind of figured that if a cat con is getting clogged there'd be some sort of warning in the seat of my pants. Yes, it had been blowing a CEL randomly, like once or twice a day for the past week, but it still ran perfect - right up until it quit on me. That's kind of what I'm concerned about, is it normal to go from everything's fine to clogged up and stuck on the side of the freeway in about a mile or so? And at that point the engine is just compressing air into a clogged exhaust with a very limited relief - can that damage anything? I've just never experienced anything like this that wasn't mechanical in nature. I'm really hoping the engine is fine.
 
Yep, happened to me. Zero power, virtually no vacuum on my vacuum gauge. No codes. Got hot. Called in a flatbed. 3rd cat was clogged.

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I should probably clarify the above: Yesterday the Jeep went from 70 MPH in the left lane to stumbling with no power with me signaling right and bailing onto the right shoulder in maybe a mile. After about a half hour of cooling things down I was able to limp it maybe another 1/2 mile to the next exit and I shut it down again. I got home via Uuuber, came back with my truck and towed it home. I have no intention on driving it in this state.

I kind of figured that if a cat con is getting clogged there'd be some sort of warning in the seat of my pants. Yes, it had been blowing a CEL randomly, like once or twice a day for the past week, but it still ran perfect - right up until it quit on me. That's kind of what I'm concerned about, is it normal to go from everything's fine to clogged up and stuck on the side of the freeway in about a mile or so? And at that point the engine is just compressing air into a clogged exhaust with a very limited relief - can that damage anything? I've just never experienced anything like this that wasn't mechanical in nature. I'm really hoping the engine is fine.

Mine was going probably 80mph when all of a sudden I was in limp mode and pulling to the right. I was lucky that after a reset I could get back up to 55 but every time I exceeded it, limp mode until I reset with the scanner.
 
Question: Has anyone ever experienced this? Is that typical behavior if you plug up a cat con? I only really made it a half mile in its running rough state, can that damage an engine?

Thanks!
I've dealt with several. Always the same, it was running fine and then it was acting like the exhaust was plugged up. In our cases, the mini cats failed and the pieces went down and plugged up the main cat. Zero codes ever.
 
the mini cats failed and the pieces went down and plugged up the main cat.
Same happened to me one of my vehicles. Driving 60 MPH and the material in the pre-cat melted due to an ignition issue causing a very rich condition, then that catalyst material plugged the main cat.

Since the OP had an overly rich condition, I would definitely suspect this same thing happened.
 
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I've dealt with several. Always the same, it was running fine and then it was acting like the exhaust was plugged up. In our cases, the mini cats failed and the pieces went down and plugged up the main cat. Zero codes ever.

Same for mine. Felt like it was strangely down on power. Then there was like a dull thud or pop, then it improved.

Eventually it threw a code for efficiency about 500 miles later. Haven't cut the assembly down to check if the 3rd cat was clogged, but will get it done eventually.
 
I was driving my 90 Wagoneer back from Uwharrie National Forest many years ago and kept getting a stutter or hesitation in power on the way home. Doing 80 on the interstate and then it felt like the engine shut off for a second or two. Very hot day. Pulled over and checked plugs and wires, kept driving. Happened again and pulled over and replaced distributor, plugs, and wires. Kept driving. Happened again. Threw parts at it all the way home. Ended up not driving it for several months until I had to pass emissions to register it. It failed. Report pointed at catalytic converter. The muffler shop showed me the hollow interior. That's when I realized that the honeycomb was breaking up and clogging the exhaust. They thought I had hollowed it out.
 
I plugged the Bank 2 mini cat on my 05. Driving home from work and started to get on the throttle to merge and lost all power, CEL started flashing. I pulled over and gave it some rev's and the idle stabled. At time I do believe that I had CAT efficiency codes for a few days prior to this . Few days later I replaced the entire Cat system. The B2 cat was nearly gone, B1 was fine.

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Here's a follow-up to the original post. Took the Jeep to a recommended muffler shop last week and sure enough, the downstream cat was completely plugged up with bits and pieces of the Bank 2 pre-cat. Was not a cheap fix since Colorado has now adopted the screwy california rules of "approved" cat cons only but after putting on the new ones the Jeep runs great and the engine revs out and breathes as it should.

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