The original catalytic converter on my ‘03 R53 is rattling something fierce. And the dreaded P2096 code has popped up. I take this to mean that a weld has cracked, which, according to what I have read here, is a common problem. I am going to see if I can find somebody to re-weld the assembly.

However, if I have to replace the assembly, which brands of aftermarket catalytic converter assemblies are put together so that they are oriented/install identically to the MINI branded cat and perform properly so there are no codes to deal with? I am looking for stock/OEM fit and function.

Catalytic Converter with Integrated Exhaust Manifold brands I am aware of are:

AP / Eastern
API
Catco
Davico
Dorman
Walker

What is your experience?

 

Dorman is garbage.
I'm not familiar with the other brands.

 

Are you saying Dorman’s exhaust manifolds are garbage, or their product line in general?

Previously, I had a bit of disdain for the brand in general. However, a Ford mechanic I know likes their products for Ford.

On the list I gave, Dorman is roughly middle of the pack price-wise.

 

Across the product line.
Maybe your friend likes them because the customers come back needing their car fixed again.

 

Considering the number of enthusiasts on this forum who've changed out their stock exhaust manifolds for headers (with or without cats), there must be a bunch of low mileage, complete manifolds with stock cats sitting in their garages or attics just waiting for you to buy one. The advantages; 1) You'll know it fits 2) The stock cat will not throw a code 3) The seller will be able to tell you how many miles were on it at removal. The disadvantage: Unless it's local, you'll need to pay for shipping in addition to the price the seller charges.

 

Ha!

I notice that ECS Tuning sells the Dorman exhaust manifold assembly. I would think a reputable place like ECS would not sell it if it were problematic. But I hear you loud and clear.

 

That’s an interesting point. If I could find a low mileage takeoff...

Are the aftermarket cats of the OE design known to throw codes?

 

Some have reported that the MILLTEK header with cat have thrown a code. Others have reported that they don't. The RMW header with GESI cat does not. Both of those new are $1K+.

 

Thanks. I guess if it comes to it, the RMW is the way to go then. I appreciate your input.

 

I found this NAM thread where NAM members purchased exhaust manifold/cat assembly from mufflerexpress.com. Looks like they still exist. Anyone have any more recent info about Muffler Express’s product?