Engine misfiring caused 2 catalytic converters to clog. Once clogged, the exhaust back pressure burst the EGR valve and other emissions parts. I've had to change cat 5 times because of the recurring engine misfiring. happens on humid/rainy days. current exhaust system is a straight test pipe and no cats that i daily drive, i put stock exhaust on only for inspection times.

Manifolds are also obnoxiously placed in the most inconvenient spots for owners to change. Requires you take it to a shop. Rear bank manifold clogs up every year and never costs less than $800 to change.

Water seems to be what causes this issue. We had the same problem a couple of years ago with our 2001 Escape. Our 2003 Ford Escape, after a heavy rain, sputtered and jerked on starting. The engine warning light was blinking, there was no power in the acceleration, and there was a strong burning smell. We were stranded 2 hours from home and had to have a local mechanic look at it. He said the O2 sensor was destroyed and that had caused the catalytic converters to clog. He'd never seen anything like it. All three converters had to be replaced. He was able to do it aftermarket for about half the cost ($3000) of using manufacturer parts (about $7000). That was 8 months ago. Guess what started happening this morning after a night of heavy rain? That's right, we're about to spend another $3000 on this money pit. We will never buy another Ford.