The Official Blown Catalytic Converter Thread

[RickInJax]

Question regarding Cat warranty. Dealer replaced Pside cat under warranty, at 62,000 miles. Charged me 400 for flex pipe stating not covered. That cat has just failed again 2 1/2 yrs later and mileage is now 109,000. Are there any Fed laws regarding OEM replacement cats. Dealer is say we warranty our work for 1yr\12,000 miles.

Hi... Apdbxba..
What cat warranty are you referring to please?
I just lost a Cat on my 13 A7. Very loud and smells bad. 63K miles.
Being charged $$$ by dealer for the work.

thanks
rick

[RickInJax]

Hi Everyone:
I just had my driver's side CAT replaced at the dealer. It failed/broke and had horrible smell and very loud.
The dealer said nothing about an emission warranty on the cats.
2013 A7, 65K milies

Anyone on here have more information on cat warranty?

thanks
rick

[audistealth]

Hi Everyone:
I just had my driver's side CAT replaced at the dealer. It failed/broke and had horrible smell and very loud.
The dealer said nothing about an emission warranty on the cats.

Anyone on here have more information on cat warranty?

thanks
rick

epa.gov:

The*Clean Air Act*requires manufacturers of light-duty vehicles to provide two federal emission control warranties: (A) "Performance Warranty" and (B) "Design and Defect Warranty." These warranties are provided by the vehicle manufacturer and apply to used vehicles as well. The warranty period begins from the date of sale to the original owner.
The Performance Warranty covers repairs which are required during the first 2 years or 24,000 miles of vehicle use (whichever first occurs) because the vehicle failed an emission test.* Specified major emission control components are covered for the first 8 years or 80,000 miles (whichever first occurs). The specified major emission control components*only include the catalytic converters, the electronic emissions control unit or computer (ECU), and the onboard emissions diagnostic (OBD) device or computer. If you are a resident of an area with an Inspection and Maintenance (I/M) program that meets federal guidelines, you are eligible for this warranty protection provided that:

Your car or light-duty truck fails an approved emissions test; and

Your vehicle is less than 2 years old and has less than 24,000 miles (up to 8 years/80,000 miles for certain components); and

Your state or local government requires that you repair the vehicle; and

The test failure does not result from misuse of the vehicle or a failure to follow the manufacturers’ written maintenance instructions; and

You present the vehicle to a warranty-authorized manufacturer representative, along with evidence of the emission test failure, during the warranty period.

The Design and Defect warranty covers repair of emission control or emission related parts which fail to function or function improperly because of a defect in materials or workmanship for 2 years or 24,000 miles (whichever first occurs), and the specified major emissions control components mentioned above for 8 years or 80,000 miles (whichever first occurs). The manufacturer can deny this warranty coverage if evidence shows that the emission component failure was caused by improper use or maintenance and not caused by a defect.
A list of these components and a description of the warranties (PDF)(10 pp, 697K, EPA-420-F-15-035, October 2015)is available on our web site. However, vehicle technology is constantly changing, therefore there may be emissions control components or emissions related components which do not appear on this list. A more complete list can be found in your owner's manual/warranty booklet.*The specified major emissions control components, however, are specified in the Clean Air Act* and are the only components subject to the 8 years/80,000 mile federal emissions warranty.
When you believe you have identified a defective part, or your vehicle fails an emission test, you should follow the procedures for making a warranty claim as identified by the manufacturer in your owner’s manual or warranty booklet. If you plan to have the manufacturer pay for a repair under either of the emissions warranties, you must take the vehicle to a facility authorized by the vehicle manufacturer for repair to give them the opportunity to diagnose and repair it. Note that if your regular repair facility is not authorized by the vehicle manufacturer, they are not obligated to advise you of parts that are covered under warranty. Before giving your automotive technician the “go ahead” to perform repairs, check your owner’s manual/warranty booklet for possible warranty coverage. Additional state laws may apply, so you might want to contact your state Department of Motor Vehicles to find out.

https://www.epa.gov/transportation-a...sportation-air

[kjeeper10]

I know with jeep JK, mine had a 80k/8 year (whatever comes first) warranty on emissions parts including the cats.

[RickInJax]

epa.gov:


https://www.epa.gov/transportation-a...sportation-air

Thanks guys for your response.
My 2013 A7 only has 65K so I would believe it should be covered.
But no one said a word at the dealer.

I just emailed the dealer to see what they say. I'll keep you posted.

thanks again...

rick

[audistealth]

Thanks guys for your response.
My 2013 A7 only has 65K so I would believe it should be covered.
But no one said a word at the dealer.

I just emailed the dealer to see what they say. I'll keep you posted.

thanks again...

rick

Don't hesitate to escalate to AoA if your dealer continues to act up. They know better and played dumb.

[KLX]

Agreed. No cats are raspy.. it sounds awful. Lol

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+1 when I ran JHM test pipes the exhaust smell was just to much. The wife hated when I rolled down the windows.

[Jk79]

Anyone replaced their bad oem cat with the Magnaflow OE replacement? They’re under $500. Haven’t been able to find any reviews though.

[Jamen]

I’m looking to see if anyone has replaced with the JHM catted Xpipes. I’d like to know if there is a change to the cabin noise

[Jk79]

I’m looking to see if anyone has replaced with the JHM catted Xpipes. I’d like to know if there is a change to the cabin noise

There is a recent JHM post here with a YouTube review (it’s also on their site) by IgnitionTube. B8.5 S4 with JHM test pipes and catted downpipes/xpipe. Sounds super loud and a bit raspy.

I was considering that route too but I wouldn’t be able to take the volume.

[MagnaFlow]

Anyone replaced their bad oem cat with the Magnaflow OE replacement? They’re under $500. Haven’t been able to find any reviews though.

We know there are quite a few S4 members on here that have used our cats. They are designed to be a direct replacement for the stock converters and come with their own warranty. If we can offer any additional info about them, please feel free to drop us a PM or call at 1-800-990-0905!

[drew_doc1]

I've got JHM test pipes. No issues. However I'm not a fan of the smell and the extra loud cold starts. I'm trying to get GESI high flow Cats welded in, but unsure about the O2 sensor location. The OEM cats have an O2 sensor in the middle of the cat. The test pipes have the sensor port farther back than the new cats will be added. I may need to move the port and extend the sensor lines but unsure if that is necessary. Does anyone know if I will need to move the O2 sensor to infront of the cat or if I can leave it where it is?

[drew_doc1]

What would test pipes do in terms of drone or loudness of the car. Also what about power gains? Planning on running AWE touring but don’t want it to be too loud or drone


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I have JHM test pipes with full AWE touring exhaust. Prior to the test pipes I thought it sounded great. Test pipe smell and esp cold starts and WOT are really loud. Definite drone when accelerating, not bad when cruising.

[audistealth]

We know there are quite a few S4 members on here that have used our cats. They are designed to be a direct replacement for the stock converters and come with their own warranty. If we can offer any additional info about them, please feel free to drop us a PM or call at 1-800-990-0905!

Part number / link? High flow options?

[Robdukes]

Called a local euro repair garage the other day. Told the guy my situation with cats starting to go and he basically said they wouldn't do the job. He said they wont tamper with anything that has to do with emissions. Whether that job was putting in test pipes or relocating cats. And if I wanted to replace the cats with stock that was even iffy because he didnt have time to do it. Ill call some other shops...was just a bit surprised at how much he didnt want to do anything with the cats. Hope I dont encounter this with all the garages because im in an emissions county of PA.

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[StreetWolf]

I've replaced mine twice now first time paid the dealer bend over price after that i did some research using the dealers part number and found this site that sells original O.E. parts cheap https://www.audipartsprime.com/ i'M never ever paying dealer prices again.

[RickInJax]

Don't hesitate to escalate to AoA if your dealer continues to act up. They know better and played dumb.

Update to the community...
Audi did reimburse me $2600 for the cat replacement.
The dealer never mentioned it until I did so stick with it everyone when you have the cat issue.

Thanks again for your help!
rick

[KRp220]

We know there are quite a few S4 members on here that have used our cats. They are designed to be a direct replacement for the stock converters and come with their own warranty. If we can offer any additional info about them, please feel free to drop us a PM or call at 1-800-990-0905!

interested as well. what are the limitations of the warranty? will it be covered if we are tuned or have any sort of modifications? is the cat the material the same type as the OEM cars?

[EIAlfonso]

Update to the community...
Audi did reimburse me $2600 for the cat replacement.
The dealer never mentioned it until I did so stick with it everyone when you have the cat issue.

Thanks again for your help!
rick

Nice, slap them with a negative review with Audi/Google, thats BS. I'm assuming you are not modified or flagged TD1?

[RickInJax]

Nice, slap them with a negative review with Audi/Google, thats BS. I'm assuming you are not modified or flagged TD1?

No modifications... strictly stock.
I have not filled out their service review yet either ..

rick

[elpaisacq]

I have JHM test pipes with full AWE touring exhaust. Prior to the test pipes I thought it sounded great. Test pipe smell and esp cold starts and WOT are really loud. Definite drone when accelerating, not bad when cruising.

I am currently running the Tampa Motor Sports Test pipes and a Magnaflow Resonated Xpipe, not loud at all and smell is lower than expected.

[paramatthew]

Add me to the list.
2014 S4. bought CPO in Aug 2017 with 56k miles, now at 88k miles COMPLETELY STOCK (I drive a ton, mostly highway).
Driving on the highway 3 weeks ago and passenger side cat let go, from normal to what sounded like open headers in a split second and a CEL after shutting down/restarting.
Brought to a dealer (not where purchased) thinking it would be covered under CPO warranty, was told exhaust parts are not covered and given estimate of $4000 even. When asked to price out labor vs. part cost they were hesistant and only told me "about $2500 in labor", also didn't have the part in stock.
Had it towed to my own mechanic and waited two weeks for a Magnaflow OE replacement. $1800 in labor from them and just picked up today, seems fine but now I'm just waiting for the driver side to give out.
My mechanic, who specializes in Audis, said the welds failed and he had never seen it, this was the first cat on a B8 they've done and first under 100k miles period.

Is this worth escalating with AOA? I am still furious my "new" CPO car needed this much work after a year and a half with no real explanation why this happened IMO prematurely.

FWIW My mechanic was really impressed with the Magnaflow part and said it fit perfectly.

[scls4]

I dont have the details yet but my mechanic texted me over the weekend that he just finished replacing cats with test pipes on a B8.5 DSG in 2 hours without cutting anything......I think that's the lowest labor # I've heard by a long shot?

[Robdukes]

I dont have the details yet but my mechanic texted me over the weekend that he just finished replacing cats with test pipes on a B8.5 DSG in 2 hours without cutting anything......I think that's the lowest labor # I've heard by a long shot?

Wow. Definitely interested in details when you hear them.

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[ModItNow]

I dont have the details yet but my mechanic texted me over the weekend that he just finished replacing cats with test pipes on a B8.5 DSG in 2 hours without cutting anything......I think that's the lowest labor # I've heard by a long shot?

Might be the JHM method. Put a strap around the tranny and pull it to the side. Apprently gives enough room

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[BucDan]

Looks like the Federal and CA warranty states that it only concerns the catalytic converter itself, and if you had regular maintenance with it that showed no neglect. I don't think a dealership or AOA can say that you tampered it or tuned it if you didn't change anything BEFORE the catalytic converters.

I had my car looked at today as well, full stock tune but with a full cat back setup. The service advisor tried to tell me that it wouldn't get covered since it wasn't stock, but from what I can tell, it's covered since nothing was changed before the cats and the full cat back by definition comes after the cats, so there's no alteration.

He told me to keep an eye on it, no CELs. But I see the dust starting to appear and a richer smell on cold starts as I backup from the driveway. Does Magnaflow make CA compliant cats?

[EIAlfonso]

I dont have the details yet but my mechanic texted me over the weekend that he just finished replacing cats with test pipes on a B8.5 DSG in 2 hours without cutting anything......I think that's the lowest labor # I've heard by a long shot?

This is why I’m not a mechanic, took me over 12hrs with hacking, albeit on my back and about 3hrs on one bolt


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[KRp220]

I dont have the details yet but my mechanic texted me over the weekend that he just finished replacing cats with test pipes on a B8.5 DSG in 2 hours without cutting anything......I think that's the lowest labor # I've heard by a long shot?

jeez. where was that? i'm somewhat local and need to have cats put back in

[J_Bigs33]

Also having similar issues pointing to a bad cat on bank 2. Looking to go the Magnaflow route as I've heard nothing but good things with part numbers 49135/49136 as far as fitment, price and longevity compared to factory. Would like a little more feedback from everyone in terms of useage with these. Def will put in a call to MF tomorrow and talk to them as well

[scls4]

jeez. where was that? i'm somewhat local and need to have cats put back in

VW Garage in Westbrook, Maine (he just moved his shop to a bigger place last week). His name is Corey.
https://www.facebook.com/theVWgarage/

Tell him white s4 sent him.

[BLKPERL]

Is CAT failure happening to mostly dsg or manual? Affecting any specific years?

[Jk79]

Is CAT failure happening to mostly dsg or manual? Affecting any specific years?

Didn’t think to ask about trans type but there are some responses here regarding cats vs tunes etc. Cat issues don’t seem to have a clear root cause (based on some research myself)

https://www.audizine.com/forum/showt...our-stock-cats

[Robdukes]

Didn’t think to ask about trans type but there are some responses here regarding cats vs tunes etc. Cat issues don’t seem to have a clear root cause (based on some research myself)

https://www.audizine.com/forum/showt...our-stock-cats

I can't speak for anyone else but my cats never gave the sulfer smell until I went stage 1. Literally my first ride after tuning I went on the highway and opened it up and the smell followed. The increased temperature from more boost made the eventual issue known.

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[BigKeshy]

I can't seem to find how cat removal for the 6MT compare to DSG cars with respect to the space available to pull them out? I know about the JHM method with straps to pull the DSG tranny off to the side a bit to clear the passenger cat, but is there more room available in the 6MT?

If so, is it still necessary to sag the trans w/ 6MT?

[EIAlfonso]

I can't seem to find how cat removal for the 6MT compare to DSG cars with respect to the space available to pull them out? I know about the JHM method with straps to pull the DSG tranny off to the side a bit to clear the passenger cat, but is there more room available in the 6MT?

If so, is it still necessary to sag the trans w/ 6MT?

There’s more room available with the 6MT and yes you need to sag transmission
There’s a DIY within in the mertrop long tube headers thread, using a 6MT


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[BigKeshy]

There’s more room available with the 6MT and yes you need to sag transmission
There’s a DIY within in the mertrop long tube headers thread, using a 6MT

Thanks! I appreciate the help!

[MagnaFlow]

Part number / link? High flow options?

interested as well. what are the limitations of the warranty? will it be covered if we are tuned or have any sort of modifications? is the cat the material the same type as the OEM cars?

He told me to keep an eye on it, no CELs. But I see the dust starting to appear and a richer smell on cold starts as I backup from the driveway. Does Magnaflow make CA compliant cats?

Also having similar issues pointing to a bad cat on bank 2. Looking to go the Magnaflow route as I've heard nothing but good things with part numbers 49135/49136 as far as fitment, price and longevity compared to factory. Would like a little more feedback from everyone in terms of useage with these. Def will put in a call to MF tomorrow and talk to them as well

At this time we do not offer any 'high flow' catalytic converters; all of our units are designed to be direct replacements for the stock units. We cover all federal cats with a 2yr/25K mile warranty on the catalyst element and 5yr/50k mile warranty on the cat body construction. We will not deny the warranty strictly because of a tune, but there are many aftermarket tunes don't use the proper AFR's. If we have the cat in for inspection and determine it failed due to improper AFRs, we will be unable to cover it.

We currently offer federal legal units and have some CARB legal units in development now.

49135 - Federal, OEM grade, direct fit, left side
49136 - Federal, OEM grade, direct fit, right side

Feel free to give us a call anytime during the week at 1-800-990-0905 if you'd like more info on them!

[cssullivan]

I have a 2015 with 36k on it, which only gets roughly 10mi of driving a day with some spirited pulls here and there. I noticed recently when sitting at a stop light some light smoke/exhaust fumes in my rear view mirror. Thought it was a little strange when its 75 degress out to be seeing this, but no notice of smell or white particles from exhaust. Any thoughts on if this is normal or potential early signs of blown cats?

(posted this in another thread, this is probably the better spot for it)

[Jk79]

I have a 2015 with 36k on it, which only gets roughly 10mi of driving a day with some spirited pulls here and there. I noticed recently when sitting at a stop light some light smoke/exhaust fumes in my rear view mirror. Thought it was a little strange when its 75 degress out to be seeing this, but no notice of smell or white particles from exhaust. Any thoughts on if this is normal or potential early signs of blown cats?

(posted this in another thread, this is probably the better spot for it)

Seems more likely to be just burning off water in the exhaust. Especially if you do a lot of short drives. If it was a cat issue you’d normally see other symptoms like reduced gas mileage, change in exhaust note and misfires on wot.

[cssullivan]

Seems more likely to be just burning off water in the exhaust. Especially if you do a lot of short drives. If it was a cat issue you’d normally see other symptoms like reduced gas mileage, change in exhaust note and misfires on wot.

Gotcha. Appreciate the feedback.


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