Contour Enthusiasts Group Archives Forums General Troubleshooting questions about catalytic converter and warranty

I've done some homework on this topic (read about 30 previous threads) but still have a few questions regarding the catalytic converter and the emissions warranty...

1) How can I find out FOR SURE how long the emissions warranty is for my 95 Contour SE? Car has 71,000 miles and some engine issues that appear to be cat-related-- the 2 hoses between the DPFE and the big metal EGR tube keep coming off whenever I drive the car, and the car has run so rough for 4 months that it's probably been like that for a while. I've heard the emissions warranty (the long one that includes the cat and some other stuff) is 5yr/50k mile on some Tours, 8yr/80k mile on others, etc. Also, what items are covered by the "long" emissions warranty - the main cat, the pre-cats, PCM, etc.?

2) Are other items fixed free under the emissions warranty if they break due to failure of a covered component? I've seen mention of this in other threads but wasn't sure if it was true. E.g. if a bad cat causes the O2 sensor to go bad, the O2 sensor replacement would be free?

3) Can someone explain briefly the cat-related stuff on the Contique? I've seen mention of the main catalytic converter and a couple of pre-cats, but I don't understand where they're located, etc.

4) If the cat was already replaced once under warranty or recall, will Ford replace it under warranty again, if it turns out the replacement cat has gone bad? A previous owner had the 97E61 recall done on 12/29/1998, but I don't know if anything was replaced, or WHAT was replaced, or if things were just inspected and determined to be okay.

Before I take the car in to a dealer, I want to be clear on what is and is not covered. I don't trust the dealers on something like that, and the Ford 800# phone rep was friendly but useless. She indicated nothing is covered on my car beyond 5 yrs/50k miles. I'm pretty sure my warranty booklet mentions the 8yr/80k mile emissions coverage. I guess I should re-read it.

there is a federal law the states that emissions systems on viehicles produced after a certain year (not sure what it is) must be warranted for I think 8 years, and definately 80,000 miles

Thanks jsmith. I didn't realize that the determining factor for the 8/80 coverage was a federal law, and not just a Ford policy decision/change.

I did not know there was an 8/80 warranty on anything.

But looks like it only covers catalytic converter and OBD device...

http://auto.consumerguide.com/auto/editorial/advice/index.cfm?act=warranty

Oh and elsewhere on that site it indicated that the 8/80 began w/ '95 model year.

Reading your warranty book is a good place to start as it will tell you the minimum warranty you have, however, certain things may have additional coverage (e.g. I have 10 years on underhood wiring harness - written advice from Ford a year or so ago). For these latter items you are at mercy of dealer if you were not registered with Ford at the time of issue and former owner did not pass info along.

On the v6 the pre-cats, as some are calling them, are between the oxygen sensors. In fact they are part of the exhaust manifold.

Catalytics are covered for 8yrs/130,000km on my cars and the Contour (120,000km) has had the hoses you mention coming off for the past six months. It was only by reading the cat plugged post on this board that I learned about true cause.

Consequential damages are rarely if ever covered by warranties.

horseydug, thanks.

Your Contour has had the same hoses coming off for 6 months. How has your car been running during that time? My Contour had very little power, objected to revving and accelerating, fuel economy about 25% less than normal, etc. In other words, obvious indications that something wasn't right.

Did you resolve your problem by having the catalytic converter replaced under warranty, or via something else?

The actual emmision systems components will be covered by the 8/80 warranty. If there is another problem that causes these things to fail, it will be difficult to get any warranty relief. The EGR tubing and valves should be covered. If this tube is separating due to excess pressure, there is probably some other related problem causing this.

To clarify: are the pre-cats and O2 sensors considered emissions system components?

Yes, but only the cats are covered by the 8yr warranty.
I have not had mine replaced yet.
More on my story later.

My story (short form):
Exhaust leak heard at back of engine
Diagnosed as EGR-to-manifold tube
New tube purchased, old tube in excellent condition removed at which time existence of hoses discovered. One was missing, one off but jammed low in engine compartment.
New EGR tube and hoses installed and hoses subsequently blew off.

Other than exhaust gas smell and driving with window slighly down (normal for us nicotine addicts) no noticeable affect on peformance, however there must be some since the EGR valve would not be getting pressure or flow info.

Like I mentioned earlier I just recently read about plugged cats, and increased back pressure blowing these hoses and haven't got car to dealer yet.

i dont have much to add to what other have said but my car had the recall emissions work performed back in 97 (i bought car last yr) so i dont know what all was involved...there is however a sticker that goes underhood on the strut tower that tells u what recall was done and when....goin off the top of my head i think mines shows that the cat and the manifold were replaced

check with the dealer, or a couple dealers to see about recalls and warranty repairs....i had a couple of recalls taken care of in jan/feb...one for the fan switch i think and one that is simply a check of the wiring harness somewhere underhood...if its damaged they replace if not they do nothing....and there was one recall that the service guy told me had expired 12/31/01 but after checking around i think it is still an open recall so i will be heading to another dealer to ask

edit

okay i just went out and checked what my sticker says...

REPLACE CATALYST/EXHAUST MANIFOLD ASSEMBLY

CHANGE AUTHORITY: EMISSIONS RECALL 96E60

DATE: 10/97

FYI