Catalytic Converter Causes Rattling Sound

A defect as simple as a thermostat stuck open or a bad spark plug can cause the failure of a catalytic converter. Rapid temperature changes can also cause damage. The cat normally operates at temperatures above 400 degrees Fahrenheit. Rapid cooling can cause the internal ceramic structure to break apart and obstruct the exit into the exhaust pipe. Engine management defects that allow too much fuel into the cat can also cause the honeycomb structure to break apart. When the cat becomes plugged there is a noticeable drop in engine power. In addition, the check engine light may turn on.

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Broken catalytic converter created loud rattle when vehicle was idiling