Catalytic Converter Rattle

Have read other forums on this topic and it was covered by Toyota with over 100K miles at no cost.
I have a 2008 Tacoma automatic 4cyl with 175K miles bought new in 2009. About 5-6 years ago I noticed a rattle, with motor off, exiting truck closing door.
When having oil changed I ask if there were loose parts that would cause the rattle each time the answer was no.
Recently a vibrating rattling noise started when accelerating. Took it to the dealer they said it's the catalytic converter, I ask if this could be a warranty item they said no.
At home with the motor off, using a rubber mallet I can duplicate the rattling sound I've heard for the past 5-6 years.
Here's my question with the age and mileage on my Tacoma could this be covered under a hidden warranty?

 

Is the rattle the catalytic material inside the converter, or the heat shield banging about on the outside?

The heat-shield is the most common, and can be fixed with a couple of clamps in most cases.

If it's the inside, it's a failure that will eventually set codes and/or clog up to prevent running (think potato in the tailpipe).

Even though some federal mandates exist for extended emissions warranties beyond regular warranties, I think you are well beyond that as they are for 8/80 IIRC.

Hopefully it's the shield.

 

This has happend to my 4 cylinder too. It is covered threw Toyota to get the cat changed out at no charge. It is a factory recall

 

His truck is older than the Service Campaign (not recall) that our trucks fell under.

https://www.tacomaworld.com/threads...vice-campaign-2010-2014-4-cyl-tacomas.399785/

 

I had the same rattle for awhile and it wasn't till my neighbor (same Tacoma as mine) told me about the rattle noise he had, which was remedied by a $2.00 stainless steel worm gear clamp. I installed it 5 years ago and to this day, no more rattling.

 

The rattle is the honeycomb shaped material inside the converter. We removed the heat shield to verify. i've had the oil changed over the past 5-6 years by Toyota dealers and independents and have ask to check for loose parts because of the rattle when closing the door. The rattling noise, when driving, started recently and only heard when hard acceleration or when the transmission down shifts.
Well with that being said, does anyone have a recommended parts supplier for OEM or aftermarket and which aftermarket parts to avoid?

 

Need suggestion for Catalytic Converter replacement.
Local Toyota dealer quote over the counter 2008 Tacoma 4cyl 2.7 Ltr $1,789.65 plus tax.
Toyota Dealer on line quote $1,180 plus shipping.
Looking to buy aftermarket brand like MagnaFlow, Walker, Bosal, Eastern Catalytic. This would be Direct Fit no cutting or welding required.
Can anyone give their experience with any of these brands?

 

mine did the same what i did removed cat gutted the inside honey comb out put back on people say you cant do this cause will make check engine light to come on i never had it happen plus i know 4 other guys done same no more rattle save your money

 

Mine was on so long it rusted out and I had to replace it a few months ago. I forgot I did it and when I investigated there it was hanging. LOL!

 

Contact a couple of local muffler shops for brands they use, warranties, install pricing.

 

Are you in CA? I hope not because 2nd gens don't have any CARB compliant aftermarket cat options available...have to go with OEM in that case. Us 1st gen CA owners are fortunate in that we do have aftermarket CARB options but 2nd gens don't.

If you aren't in CA (or some parts of NY I think) then I would go with Magnaflow...they have a good reputation for their cats. Nothing will compare in quality to OEM but OEM is expensive for a reason.

 

Magnaflow does make CA-compliant cats for the 2nd Gen. . at least for the 2.7, not sure of the 4.0. I replaced both of mine at the beginning of the year in order to clear a code & have it smogged. I think Magnaflow just received certification within the last year for trucks newer than 07, not sure up to what year. This was a godsend for me as otherwise I would have had to buy OEM cats.

Regardless of CARB, I agree with you about Magnaflow’s reputation.

 

That's good to know, and even better for you 2nd gen CA guys lol...I may have just been thinking about 4.0s, not sure....just what I was told by the shop but that was about a year ago. Toyota cats are stupid expensive. Had to replace both of mine last year to pass smog and Toyota wanted nearly $3k for both installed....got a shop to put in my CARB Magnaflows instead for $600 out the door, can't beat that. Been on for nearly a year now and still going strong.

I have heard however from numerous people that no aftermarket cat comes close to the quality of an OEM cat but I suppose that's why they're so much more expensive...If I get a few years at least out of my Magnaflows I'll be happy.

 

even an OEM cat can get taken out by a flailing, spinning driveshaft at freeway speeds after a u-joint fails

 

Just checked the magnaflow website. No options for 4.0

 

Maine too now. There’s one CARB compliant cat for 2nd gens from dorman, but that and OEM are your only options.

 

I had my catalytic replaced about three months ago. Mine was doing the rattling and then I started getting decreased performance. Took it to the dealer, they suggested I contact Toyota to see if they would help as it 2010-2014 2.7 had a recall on their converters. I was told it was the same part number for 2008 as it was for 2010 to 14. I contacted Toyota and spoke to representative. He went over my service history of my truck at the dealership and told me he call me back in about three days. When he called back, he asked if I was OK paying $233 and change to have my converter replaced. I took it to the dealer to days later, got my catalytic converter replaced I was only charge the $233. They did this as a goodwill because it’s the same part number as the affected years and my history at the dealership.

 

I just went through this rattle mess. I thought it must be my catalytic converter, since holding the heat shield did not affect the rattle as I tapped on the exhaust. Started tightening a band clamp around the heat shield like others have done, but the rattle was still not affected. Then I saw it. The old band clamp from the shield had rusted and broken. It slid down the exhaust pipe and was hiding behind the frame. I then pulled it off and replaced it with a new band clamp. No more rattle. Glad it wasn't the catalytic converter.

 

Thanks for this old thread, guys! Lots of good info here. I'm up to 274k on my 2009 now, and a new rattle has turned up this week. Thanks to you, after crawling under, I know I just need a clamp. Had to bolster the rattling heat shield years ago with a fender washer in a spot or two, so it shouldn't surprise me that something else got rusty/loose/gone.

 

My 2014 fell victim to the same rattle... thankfully the rattle was the band clamp, not the cat.

My question is this... do i need the top and bottom driver side cat heat shields? Are the metal casings only there so someone doesn't crawl under and touch the hot cat, or are they necessary? Mine fell of at some point. Here is a diagram with the parts I will need:


If it makes a difference, the upper heat shield that mounts to the underside of the cab is still there.

Thanks!