2001 Ford Escape 4x4 v6 Automatic

Symptoms over time were:

1. 1st issue was Smelly Ether, varnish lighter fluid vapor smell.
2. Hard starting and rough idle.
3. Then the Transmission shifting issues and slipping.
4. Then EGR Valve blew a hole out the side 2 times
5. Then power loss.

Problem found early on was:
1. Warped intake manifold causing air leak found by spraying starter fluid around lower intake manifold causing rise in rpms. I replaced O-Rings and also added a good bead of RTV sealer.

2. Dropped exhaust pipe below cats and exposed rear cat. It looked good on bottom but when I rodded out the cat the pieces that fell out looked fused together. I drilled a hole in the front CAT and rodded it out with a 3/8th in extension. I could tell it was bad and when the broken pieces fell out they looked worse than the rear! I used a shop vac with a 1.5in hose to suck out the broken CAT pieces. I bolted everything back up. The truck ran very well despite the exhaust leak from the dime size hole I drilled to rod out the front CAT.

Now I just need to go to the muffler shop and get that hole spot welded.

Reason for issues:

Leaky intake manifold o-rings due to warped part cause excess fuel to dump into CATS casing CAT's to fail and plug up. This then caused transmission to not engauge properly casing slippage. Then later causing back pressure in engine decreasing power and blowing out EGR valve.


Earlier Ford dealer said it needed $800 fuel pump service and or $800 transmission solenoid. WRONG! They also said worn out timing chain… WRONG! Also said fuel injectors. WRONG!

I also had changed trans oil, no help.


So bottom line is CHECK INTAKE O-RINGS and CATS!