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Update to this post. 40,000 miles later, the first catalytic converter failed again - found during emissions test. Mechanic quoted $1,800 for the Ford provided replacement part plus $385 labor (even though the after-market part is less then half that cost). That's $5,000 in catalytic converter replacement costs in just 130,000 miles. Mechanic reports that this is a very well known issue with the 2004 Escapes.Report it
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