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Discussion Starter #1 (Edited)
2003 Santa Fe, 2.4 4 cyl.

I got a P0421 code recently, so I thought I'd take a look at the cat and the O2 sensors to see what was going on, if they could be cleaned, etc. This is what I found:
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Looks like the top substrate has completely melted.
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Downstream O2 sensor also looks heat distorted.
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Upstream sensor looks OK -- hope so, because I can't even get it to budge.

So, I'm guessing that I'll be replacing the cat and the downstream sensor -- no other possible fix. Would this be correct?
 

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wow. obviuosly Your cataylitic converter has melted from extreme heat. downstream 02 sensor also needs replacing it must of trigered some kind of Yellow check engine soon light on the dash way before it came too this point to worn you? You need to get this diagnosed properly too find the root cause of this Before replacing Your cat & 02 sensor with a new one. or same thing will happen again with those parts all over again.
 

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Discussion Starter #3
No CEL other than the P0421 -- and when I clear the code it stays off for awhile.

Both O2 sensor readings seemed to fluctuate within normal parameters.
 
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