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DISCO3.CO.UK > Faults & Fixes (D4)

Catalytic Converter studs sheered off

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Pedros

Member Since: 25 Jun 2011
Location: Cumbria
Posts: 454

2010 Discovery 4 3.0 TDV6 XS Auto Santorini Black

Catalytic Converter studs sheered off

An ominous rumbling rattling noise has appeared on the underside of my 2010 Disco 4. It sounded tinny, so I expected the exhaust was knocking on something. Had a look and it transpires that the studs at the back of the cat have sheered off. They are captive studs it appears. The cat itself and pipes look fine. Obviously I really don't want to shell out for a new cat if it can be helped. So I wondered if anyone has come across this and if there's a solution. Maybe drilling out and using nuts & bolts or if it's a common problem, maybe there's a clamp someone makes. Open to suggestions.

9th Jul 2020 4:25 pm

DSL
Keeper of the wheelie bin

Member Since: 11 May 2006
Location: Off again! :-)
Posts: 72771

Someone tried to steal the cat?

9th Jul 2020 4:27 pm

Disco_Mikey

Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20726

2005 Discovery 3 TDV6 HSE Auto Cairns Blue

Have some VERY corroded nuts and studs, but never enough to fall apart

Good news is (if someone hasn't tried to steal it

) is the old studs can be knocked out (with heat) and secured with nuts and bolts My D3 Build Thread

TDV8 Retrofit Build Thread

9th Jul 2020 4:32 pm

Pedros

Member Since: 25 Jun 2011
Location: Cumbria
Posts: 454

I don't THINK someone's tried to steal it. The remains of the nuts/studs do look pretty much like unrecognisable blobs of metal.

Disco_Mikey - thanks a lot for that. Encouraging. I shall see if I can find someone to do that.

9th Jul 2020 5:16 pm

Pedros

Member Since: 25 Jun 2011
Location: Cumbria
Posts: 454

Just a wee update. The bolts had broken (rather than having been cut in an attempted theft). Probably one of the three bolts had been holding on for a good while. Had to take the cat out to get to the remains of the studs on it. They were well and truly stuck. No amount of heat and a big hammer would move them, although we didn't want to get to the point where too much force might have damaged the flange. I wonder if perhaps the bolts were a bit inferior. Anyway, took it to an engineering workshop and they kindly drilled them out, they said there was no way they were coming out otherwise. Put it all back together and all is good now. Hopefully.

17th Jul 2020 12:30 am

Discoveringcomfort

Member Since: 16 Sep 2015
Location: Berkshire
Posts: 637

2005 Discovery 3 4.4 V8 HSE Auto Zambezi Silver

Good to know it is fixed. I have never understood the use of steel nuts on an exhaust. The heat cycle promotes rust errosion and hardens the steel at the same time. It took me two days when I wanted to change my prop, one whole day to drill out the two bolts on my exhaust. Series 1 V8
Series 2 Hibrid V8
Discovery 3 HSE V8

17th Jul 2020 6:28 am

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