Cracked Catalytic Converter
 

Background:

2009 with 120,000 - Recently noticed an issue with the exhaust sound and started smelling fumes in the cabin. I took the car in and they were able to show me the soot on the flange of the catalytic converter (not sure if bank 1 or bank 2) where the crack is located.

Horrible news:

They informed me that the only way to change this cat out is to remove the engine. The cost for this repair is around the $2500 mark.

I came here hoping that somebody might have an idea that might allow me to skip having the engine removed. I discussed it with my farmer step-father and we took a look at it to potentially MIG weld it but we don't think that we would be able to cover the entire crack. I have to imagine that using a high heat epoxy would have the same issues.

Are there any other options that I could consider?

Thanks for the help.

Check out an exhaust shop with a good reputation.

Don't consider any form of epoxy repair - unless you want to torch the car after a short drive.

As mentioned above, shop for a performance exhaust shop that does custom installations, this type of shop will have the skill set and equipment to repair in place - if that is a potential option.

I would probably opt to get this fixed sooner than later in any case. Cracks in the catalytic converter was a well documented cause for the demise of many QR25DE Altima engines. The crack allows air into the CC which causes it to run much hotter than normal and the catalyst material disintegrates. Debris is pulled back into the motor and is essentially like running sand through the cylinders causing severe piston ring wear.

That's exactly what happened to my 06 Maxima. Nissan replaced the long block motor under warranty.