M-Class (W163) Produced 1998-2005: ML 230, ML 320, ML 350, ML 400 CDI, ML 430, ML 500, ML 270 CDI

Cracked Catalytic Converter

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Old 11-23-2004, 09:11 AM
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Cracked Catalytic Converter

Guess it's that time, when problems start showing up! 147000km.

At $2000.00cdn to replace the left side, I'm trying to take the cheaper way out and get it repaired (welded). From what I've read, seems to be a lot involved in getting it out of there.

Here's a thought.......and looking for feedback!

Unbolt the Exhaust from the manifold.
Cut the pipe on the straight section just before the bracket at the Transmission crossbar.
Disconnect the sensors and wiggle the CAT out of there.

Get the CAT welded at the crack. Wiggle back into place and bolt to manifold.
Weld the Cut in the Pipe.

Would this not work? Avoids dismantling the Torsion Bar, etc. Saves time and money?
Any comments? Thanks for all input!
Old 11-23-2004, 10:02 AM
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2000 ML430
Originally Posted by drummerboy
Guess it's that time, when problems start showing up! 147000km.

At $2000.00cdn to replace the left side, I'm trying to take the cheaper way out and get it repaired (welded). From what I've read, seems to be a lot involved in getting it out of there.

Here's a thought.......and looking for feedback!

Unbolt the Exhaust from the manifold.
Cut the pipe on the straight section just before the bracket at the Transmission crossbar.
Disconnect the sensors and wiggle the CAT out of there.

Get the CAT welded at the crack. Wiggle back into place and bolt to manifold.
Weld the Cut in the Pipe.

Would this not work? Avoids dismantling the Torsion Bar, etc. Saves time and money?
Any comments? Thanks for all input!
Yes you can get it down that way.... Just have to do more welding when you put it back together... I had the same problem some time ago, and I had the cats rewelded. No problems since. Make sure that the catalyst is still good ...because of the high milage on the truck
Old 11-23-2004, 10:28 AM
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Originally Posted by 00ML430 Bulldog
Yes you can get it down that way.... Just have to do more welding when you put it back together... I had the same problem some time ago, and I had the cats rewelded. No problems since. Make sure that the catalyst is still good ...because of the high milage on the truck
Thanks Bulldog!
It's cracked on one side, so I wasn't going to completely break it apart! The truck runs great, so I'm guessing it's ok.

I don't know of what to look for when checking the catalyst!
Thanks Again!
Old 11-23-2004, 06:50 PM
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I have never seen anybody get a left side cat out without taking the torsion bar out. The right CAN be done, but not worth the hassle IMHO.
Seriously with the reputation of cats lately rattling and clogging I would replace it.
Old 11-27-2004, 10:07 AM
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Just an Update!

Temporary Fix.
Bought me a Muffler Patch from Crappy Tire and wrapped it good. Noise gone and not leaking! Till I can afford to make a decision!
I also inspected the other side.......what looks like a hairline crack developing.
Old 11-27-2004, 10:16 AM
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Probably IS a crack developing.... Bite the bullet, trade it or replace both cats.
Old 11-27-2004, 02:39 PM
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Originally Posted by saturnstyl
Probably IS a crack developing.... Bite the bullet, trade it or replace both cats.
Thanks! I'm just gonna wait a while, probably replace it all.
She's been really good to me........I my Mercedes!!
Old 11-27-2004, 04:36 PM
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99 ML 320, 97 Porsche 993 C2S, 92 300E
Review the threads in the links below. I fixed my driver's side cat in May of this year, and so far no more problems. I've put 10K miles on since repair.

http://www.mercedesshop.com/shopforu...d.php3?t=93192
http://www.mercedesshop.com/shopforu...d.php3?t=92964
Old 11-28-2004, 09:30 AM
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Thanks for the links, RON. Well done!

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