For most Ford Expeditions, a replacement runs from a few hundred dollars to several thousand, depending on whether you use aftermarket or OEM parts and whether one or two converters must be replaced. In general, single-cat jobs tend to be cheaper than dual-cat jobs, and OEM parts carry a higher price than aftermarket equivalents.
What goes into the price
Costs are driven by the type of part, the number of converters, and labor. The car’s engine configuration, model year, and how easily the exhaust is accessed can all push prices up or down.
Parts and labor considerations
The following list explains the main factors that shape the final bill.
- Number of catalytic converters: Some Expeditions use only one catalytic converter, while others may require two. The more converters replaced, the higher the total cost.
- Part type: Aftermarket direct-fit catalytic converters are usually cheaper than OEM parts. OEM/Dealer-installed converters tend to be more expensive but are designed to match factory specifications.
- Labor rates and time: Labor costs depend on local shop rates and how accessible the exhaust system is. Expect longer labor times if the exhaust is corroded or underbody clearance is tight.
- Additional repairs or replacements: Oxygen sensors, exhaust clamps, pipes, or hangers may need replacement if they’re damaged or affected by the failure.
Conclusion: The price you pay hinges on part selection, how many converters are involved, and the condition of surrounding exhaust components.
Typical price ranges by scenario
Below are commonly observed ranges for Ford Expeditions in the United States, including parts and labor. Actual prices vary by year, model, location, and shop policies.
- Single catalytic converter replacement (one cat):
Aftermarket direct-fit: roughly $350–$700 total.
OEM direct-fit: roughly $950–$1,900 total.
- Dual catalytic converters replacement (two cats, if applicable):
Aftermarket: roughly $1,000–$2,400 total.
OEM: roughly $2,000–$4,500 total.
- Diagnostics and incidental work (e.g., sensor replacement, minor exhaust repairs):
Approximately $50–$200 on top of the replacement cost, depending on the diagnostic effort and parts needed.
Conclusion: For most Expeditions, expect a single-cat replacement to fall in the low thousands if using OEM parts, with aftermarket ones usually being cheaper. If two converters are required or if extensive exhaust work is needed, the bill rises accordingly.
Tips to avoid overpaying
To protect yourself from surprises, compare multiple written estimates, ask for a breakdown of parts vs. labor, confirm whether taxes and disposal fees are included, and verify warranty terms on both parts and labor.
Summary
The cost to replace a catalytic converter on a Ford Expedition varies widely: a typical single-cat job with aftermarket parts often runs a few hundred to around a thousand dollars, while OEM parts can push the total toward two thousand dollars or more. If the vehicle requires two converters or if additional repairs are necessary, costs can rise to several thousand dollars. Always obtain a detailed, written estimate and consider regional labor rates when planning the repair.