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Old 02-11-2015, 06:08 PM   #1
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2004 stage one cobra cats

Picked up a 2004 Roush Stage one Cobra about 3 months ago,
one of one made
6 speed red coupe,

and the service engine light came on,
after doing my inspections and turning up nothing I took it to my shop
they ran the diagnostic on the car and put it on the rack to find
that the front cats where bad, the back cats had been taking out

so trying to figure out the fix, and I have not talked to the muffler shop yet
so thought I'd check here

and it looked like there where 4 OEM set ups on ebay that just sold
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Old 02-11-2015, 06:40 PM   #2
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Your least expensive option is to find a good used factory catted mid-pipe. Any one off of a 96-04 V8 car will work. Try Craigslist.
Or a muffler shop will be able to weld in new cats but they can get kind of pricey.
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Old 02-11-2015, 07:53 PM   #3
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I highly doubt that car has 4 catalytic converters, or had 4. But before you buy a replacement, make sure if your car is a cali. or federal emissions car. Put the wrong converter on will not fix the engine light. I found out the hard way...


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Old 02-11-2015, 07:57 PM   #4
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Quote:
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I highly doubt that car has 4 catalytic converters, or had 4. But before you buy a replacement, make sure if your car is a cali. or federal emissions car. Put the wrong converter on will not fix the engine light. I found out the hard way...


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My car has four cats.
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Old 02-11-2015, 08:14 PM   #5
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What is the reasoning behind four cats? How many o2 sensors do you have then? And I also want to see this car, my curiosity is spiked! What makes it differe t?

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Old 02-11-2015, 08:18 PM   #6
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2004 stage one cobra cats

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Originally Posted by natestang07 View Post
What is the reasoning behind four cats? How many o2 sensors do you have then? And I also want to see this car, my curiosity is spiked! What makes it differe t?

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It's completely unnecessary to have 4 cats. Probably just another way ford would get your money. The O2 sensors are probably before the first two and the after the second ones.
Most likely it's special because it the only cobra with the stage one Roush package added from the factory...


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Old 02-11-2015, 08:34 PM   #7
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Lol.
No. They all have 4 cats. I suspect that they used that many because of space restrictions. They are very small so it probably takes four of them to have enough of the media where they get the job done and don't burn out in a very short time like a "high flow" cat will.
The 02 sensor setup is exactly as Recon described.
And you may be on to something Recon... That car may have been equipped from Roush with only two "high flow" cats installed. Hence why the two catalytic converters on the car are already burnt out before 20k miles.
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Old 02-11-2015, 08:42 PM   #8
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2004 stage one cobra cats

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Lol.

No. They all have 4 cats. I suspect that they used that many because of space restrictions. They are very small so it probably takes four of them to have enough of the media where they get the job done and don't burn out in a very short time like a "high flow" cat will.

The 02 sensor setup is exactly as Recon described.

And you may be on to something Recon... That car may have been equipped from Roush with only two "high flow" cats installed. Hence why the two catalytic converters on the car are already burnt out before 20k miles.

I'm an auto tech, it's my job to know this....
And I own a Roush, that would be my only guess at the rarity. But interesting note is in 2002 Roush converted 2 01 Cobras into 02 Roush Cobras.
I'm actually looking in buying my second Roush...

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Old 02-11-2015, 08:51 PM   #9
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Lol.
No. They all have 4 cats. I suspect that they used that many because of space restrictions. They are very small so it probably takes four of them to have enough of the media where they get the job done and don't burn out in a very short time like a "high flow" cat will.
The 02 sensor setup is exactly as Recon described.
And you may be on to something Recon... That car may have been equipped from Roush with only two "high flow" cats installed. Hence why the two catalytic converters on the car are already burnt out before 20k miles.
So it is so tight down there they can't fit a normal sized cat? That sounds terrible for exhaust work lol

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Old 02-11-2015, 08:55 PM   #10
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2004 stage one cobra cats

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So it is so tight down there they can't fit a normal sized cat? That sounds terrible for exhaust work lol

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There's probably not enough room to safely position two proper sized cats. And you can't really mount them in the back because it wouldn't be as efficient...


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Old 02-11-2015, 08:56 PM   #11
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Originally Posted by The Great Recon View Post
There's probably not enough room to safely position a proper sized cats. And you can't really mount them in the back because it wouldn't be as efficient...


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How do you figure out what set of cat is bad with that o2 setup?

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Old 02-11-2015, 08:59 PM   #12
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How do you figure out what set of cat is bad with that o2 setup?

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Looked at the set ups the second set of O2 sensors are mounted in the second set of cats...


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Old 02-11-2015, 09:05 PM   #13
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Looked at the set ups the second set of O2 sensors are mounted in the second set of cats...


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Hmmmmmm interesting. So could his code be from the o2s not being turned off

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Old 02-11-2015, 09:12 PM   #14
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Hmmmmmm interesting. So could his code be from the o2s not being turned off

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Possibly, but it would not be a very good thing to turn the O2 sensor off...


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Old 02-11-2015, 09:20 PM   #15
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These cars are pretty cramped for space so the cats are stuffed into the footwells. If they put two larger cats, it would have cost interior room. Or if they hung them under the car, they would undoubtedly scrape.
If you ever want to see a factory exhaust system that is a pure masterpiece, look at a first generation Lightning. They only had two cats but those trucks (And Ford trucks in general) are very difficult to fit a "true" dual exhaust. Everything needs to fit into the space, on one side, that previously held the single exhaust system. Ford built them from Stainless Steel and they are beautiful the way that everything is staggered and tucked up into a very small space.
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Old 02-11-2015, 09:27 PM   #16
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Looked at the set ups the second set of O2 sensors are mounted in the second set of cats...


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The "downstreams" are mounted AFTER the last cat, on the exhaust pipe. Not on it.

The reason to turn those downstreams off is, if you don't have any cats, or they aren't functioning properly, you can turn off the downstreams so that the CEL won't be triggered by the 02's sensing the increased emissions from the non-functioning catalytic converter.
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Old 02-11-2015, 09:59 PM   #17
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The "downstreams" are mounted AFTER the last cat, on the exhaust pipe. Not on it.



The reason to turn those downstreams off is, if you don't have any cats, or they aren't functioning properly, you can turn off the downstreams so that the CEL won't be triggered by the 02's sensing the increased emissions from the non-functioning catalytic converter.

My mistake I was looking at the six cylinder exhaust system...



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Old 02-12-2015, 09:21 AM   #18
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04 cobra Roush stage ones, (a factory cobra off the show room floor) basically!
comes with 4 cats, sensors are only on the front two,
they are small and which is why they probably used 4?

the back two where probably removed and do not have sensor attachments, removed to improve the sound most likely
which is does and

it passes / passed inspection (Texas Out of state inspection)
which is tough and you have to have to get Registered


oh I might add if you call Ford,
that "H" pipe assembly with those 4 cats is $3300.00

so I'll swing by Lone Star Muffler and have the two replace
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