4.0L Catalytic Converter Delete

I'll preface this by noting that I live in a state that does not mandate emissions testing of any kind.

Quick Backstory:
I had to replace my OEM passenger side exhaust manifold a few years ago due to a faulty catalytic converter- I replaced it with a decent aftermarket manifold. Fast forward to present day and I have an exhaust leak coming out of this part. I plan to drive my truck for a lot longer and therefore have minimal interest in replacing it with the same thing. I see this as an opportunity to potentially remove all 4 catalytic converters entirely and install a new exhaust system, complete with manifolds/headers, a muffler, and all the other components out to the tailpipe.

Questions:
Is this a good idea? Specifically, are there legitimate header/manifold and exhaust system options for these engines/trucks to eliminate all 4 catalytic converters, trick the sensors, and not be annoying loud?

From the research I've done, it seems there are a few options for getting around the various exhaust sensors. Is there a tuner I can purchase that takes care of all of these? Are exhaust sensor simulators a good (and reliable) option? Will I be able to achieve correct engine backpressure?

Conclusion:
At this point I wouldn't mind spending a bit more to achieve my goal and would be looking for well made components, and doing the installation work myself (provided I don't need to weld anything).

I'd greatly appreciate any guidance you guys have, or if anyone could point me in the right direction.

 

My 06 has the 2 rear converters gone but it still has the 2 front ones. I have seen plenty of videos with these trucks not having any of the converters but I can't say if their check engine light was on or not. You could always put your own aftermarket converters on and mount the first 02 sensor behind it and it should be like factory.There are plenty of muffler choices to keep one relatively quiet without any of the converters. The way I see it you're gonna have to have a quality muffler shop do the exhaust work for you because I highly doubt you're gonna reach your end goal without a welder..

 

The secondary cats don't have sensors behind them. I haven't had them for 7+ years with no issues, and in an emissions state. The fronts I need.

OP, look up long tube headers. But be prepared to spend some $

 

There won’t be any problems with back pressure with this setup, it keeps the pipes small enough for us NA guys.
1. Doug Thorley long tube headers
2. URD U-Spec exhaust (includes equal length mid-pipe and cat-back, dual muffler system to eliminate rasp)
As for the CEL, I think a tuner can stop your vehicle from going through the process of checking the O2 sensors. But not sure on that.

 

345,000 miles and just recently had p0420 and p0430 codes again, this time it turned out to be the cats so I did the Cat Wash with good results. But if you want to spend money might as well swap them out with some Doug Thorley or other brands to ditch the cats.

 

What’s the Cat Wash? My daughters truck had those same codes, but I cleared them & haven’t popped back up yet.

 

I wouldn't jump straight to it, verify your AFRs and O2s are working correctly, fuel pressure is right, no intake air leaks, MAF sensor, etc..

 

Another brand is Cataclean. It's supposed to clean the cats

 

URD has what you need

 

but do they? I thought the O2 sims were not being sold anymore

 

DT long tubes and rear o2 sensor simulators is what the truck needed. got me past ca emissions for years. just as long as they dont take a good look and fail you on the visual. Urd had the only plug and play kit years ago but i beileve they were "split second" products, at the time anyway.

 

I used cataclean on my old CRV with good results.

 

call Gadget at URD, talk with him about products

 

Just dump straight from headers to some chrome tips into engine bay. Please post video for us. LOL. j/k

 

I think your best bet would be to go with URD catless headers and have a competent exhaust shop handle the rest. It's a great opportunity to run true dual exhaust pipes, or you can route it into a 2-into-1 collector and keep the factory cat-back, or swap in whatever setup you prefer.

A tune isn’t strictly necessary unless you’re looking to squeeze out every bit of performance from the catless setup. As for the O2 sensors, spacers are readily available online. I’ve seen people run them successfully, though sometimes a 45-degree spacer is needed, straight ones can still trigger a catalytic efficiency code in some cases.