I had several P codes for emissions over the past year+ and back in September the Right front (pax side) cat finally gave out. It broke up while driving and created enough back pressure to blow out a gasket. Limped it home and that has been all she wrote since then. I had a set of JBA shorty headers hanging around since 2007 so I decided this was finally a good time to do all of this.
Not much to say about the exhaust removal overall. I read SMJ's notes about removing the manifolds. Instead of an airsaw I decided to use a set of Tin Snips to cut the heat shields out. It probably took longer than the saw at about 15 minutes total but essentially zero dust. Just a 4 pack of harbor freight specials with left and right offsets and two straight styles made quick work of it.
mod-blueprint-for-my-2006-le-t12841.htm ... rint%20mod
PSA I purchased a matched pair of "Ultra Power" (BLUEFLOW on the box?) Direct Fit catalytic converters from RockAuto. DO NOT buy this brand The Left/Drivers side comes out perfect. The Right/Passenger side fits but the outlet flange portion is clocked incorrectly by approx 15 deg and directs the piping into the frame rail/AC lines. I tested both the stock mid-pipe and aftermarket doug thorley and neither would fit. Thought maybe it was the JBA's but I remounted the stock CAT and both the stock Mid and DT Mids fit perfectly. Then I reported it as a Manu Defect to RockAuto and requested a replacement part instead of a refund (super stupid, never do this and ALWAYS request a refund) and the second one is the same way. The package the actual part is in is labeled Blueflow so I found their site, appears to be an Alibaba affiliate in China. They don't even list the Passenger side Cat on their website so that tells me it's so terrible they stopped making it. I figured RockAuto, direct fit, good enough. I was wrong.
<Rockauto Rant> I've never had to return a factory defective item before. When you do IF you choose a replacement part instead of a refund you have to create a new order for the replacement part and pay for it first then you return the bad part and after inspection you get a refund. Not great but I understand the liability and exposure of just sending out parts. The problem is this replacement process links the two orders together, the part on the original order gets linked to the replacement order and the "Arrange a Return/Report a Problem" button is a flipped to "Request Warranty Replacement" then from the NEW order history is where you generate the actual return and refund. So now you effectively locked out the refund option on the first order and used the option on the Second order to get the refund for the first order. In my case the 2nd CAT is also defective and there is no way to initiate a return on the second part. I am attempting to deal with this with RockAuto directly.