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Sorry to take so long to reply. I had something similar happening to Panther. Then 2 weeks ago my Header/Cat welded assembly broke in two & sounded like a wimpy NASCAR.
Back together w/ a used unit from Clint Cope in CA. & Panther is one Healthy Cat again!
Before the obvious was detected, I had SES light w/ 4 codes that never made sense. Simultaniously it read: running rich, low MAP voltage, Traction Control alarm & O-2 sensor stuck lean. August RMW Dyno Tune day at MAC, Panther's runs were aborted 4 times reading too lean & low boost.
Panther is running so strong now that my tires will break loose in 1st & 2nd gear just hammering on the skinny pedal w/ clutch fully engaged (700 ft elevation here in Tulsa helps).
Now that root cause is understood, Tuners accross the country are telling me that this is common. My old exhaust lying next to the replacement used unit showed not only the failed weld, but all other welds were defective.
Check yours for the same exhaust leak.....
Mike
Now I realize that the exhaust was leaking fresh air into the system just ahead of the O-2 sensor & confused it's brain.
Rich solved his problem a little while ago. He finally passed, here is the link to that Passed or his post
"To update everyone on my ordeal: Following the advice of many on NAM, I replaced the precat O2 sensor and run a 1/4c of Acetone in a tank of gas. When back to emission (5th time) and FAILED. The Nox reading actually when UP from 1.61 to 2.16. So, Very Frustrated, I returned to my new friends at Peak Eurosport. Changed to "colder" plugs and put 3 gallons of 100 octane fuel. They strongly suggested, getting the car good HOT and if there was a line to go back another time. Just this morning, Drove to a emissions place on the opposite side of Denver (Getting her Good and HOT). When I arrived, there was a little bit of a wait but, still decided to wait, maintaining about 2000rpms (keeping up the HEAT). When I got to the bay, I told the guy that this was my sixth time and needed her to pass. He smiled and said "I'll make it pass". There must be some kind of trick because, I did pass with a 1.06 Nox. When I pulled away, the tester honked from the car that he was testing and gave me a thumbs up."
__________________ 2004 MCS-Indi Blue w/Aero Kit-3mDry CF wrpd Wing&Scoop,M7 CF Shift Knob, Alta CAI w/Blu Silicon pipe,15%Alta Pulley,Forge Header Tank, Kinetik Racing Btry,MSD Coil,Taylor Thundervolt 50 wires,e3 Spark Plugs,Powerflex Upr engine Lrg & Sml & frnt Control arm bshngs,MTH mild tune,17" Konig Hotswaps Black /Chrome Spokes w/215/40wr17 Hankook H105,H&R lwrng springs& custm mntd Strut brace,Madness 22mm swaybar,Megan Rear Lwr Control arms,IE Cat-back