I'm going to try to make the bombardment of information as easy to follow as possible. Stay with me. I've been researching this all morning.
I have engine code for Bank 1 cat below efficiency threshold. That cat is loose in it's case and rattles; I'm assuming the blow by is causing the code.
I have the engine code for bank 2; sensor 2 heat circuit (O2 sensor)
I have been fighting the cats and O2 sensors for some time now.
Replaced the cats about 30,000 miles ago with aftermarket unit and replaced all 4 O2 sensors at the same time.
(I know the cats are under warranty from the government but not sure about how to go about claiming on that; and not even sure if i can find proof of purchase for the cats. I bought them from an online retailer. They originally sent me a set that was bad right out of the box, and i exchanged a ton of emails with them. I might be able to dig up saved emails and find an order number somewhere. Also, the one local exhaust shop I've been in semi-recently had a sign up that said claims on the government warranty required a $60 diagnostics fee. (I call ####))
Options for a fix:
Anyway, For less than the price of another set of cats (~$300+) I can get a PCM4Less engine tune ($195 total) and have them remove the protocol for the cats and rear O2 sensors. Along with curing my problem, I get more power, better fuel economy and a better driving truck, all for less than replacing the sensor and cats.
Replace the one cat with a universal model and replace the O2 sensor. (With code from both sides, I'm not 100% certain if both cats are bad or if 1 cat is bad. But the one cat IS definatly loose in it's case and makes a lot of noise.) So with this route I might end up replacing both cats anyway and possibly more O2 sensors.
Brings me back to the tune, which would be an end all be all. No more cats, forget about the rear o2 sensors, and more efficiency. And save money.
Lets assume I get a tune. What to do with the cats?
Remove them and replace them with pipe (frowned upon by FED GOV and also against PA vehicle code (My truck needs to pass emissions)
Hollow them out and put them back on the truck. Looks good to the inspection shop and makes everyone happy.
Leave them as is until they cause problems or clog; (Which the might not ever do, and they show no signs of doing that right now. The truck isn't running rich or experiencing any other problems.)
Opinions or experience would be greatly appreciated. Also, I don't really want to mess with O2 simulators. I've seen a lot of people who struggled to make them work in my research.