A faulty catalytic converter can cause your Chevy Astro to fail an emissions test and possibly affect your ability to register your car. Catalytic converters can become damaged due to faulty oxygen sensors or just fail through age. Replacing one requires that you remove your Chevy Astro Catalytic Converter without damaging the rest of the exhaust system. The process is not complicated and will take you about an hour.
Slide under your Chevy Astro and locate the catalytic converter. The catalytic converter will be located between the muffler and the intake manifold of the engine. It looks like a smaller version of a muffler that is slightly flattened on both faces; the exhaust pipe runs into and out of it.
Cut the catalytic converter from the exhaust pipe using a reciprocating saw. Skip to Step 3 if your catalytic converter was bolted onto the exhaust pipe and your replacement catalytic converter will also be bolted on (if your replacement is going to be welded you can cut the old one out as well). Cut from the bottom of the exhaust pipe up, about 2 inches away from the end of the catalytic converter.
Spray penetrating lubricant onto the bolts used to attach the catalytic converter to the exhaust pipe of your Chevy Astro. Wait 5 minutes before going on to the next step.
Attach the appropriate-sized socket to the end of your impact driver (hand held). Lock the socket onto the bolt head and strike the driver with a hammer to break the bolt loose.
Remove the bolt on each end with a socket wrench and pull the catalytic converter from the exhaust pipe.
