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Failure of Cat.Cnvtr @ 58K...wassup wit dat? 850 1996

..bought this sweet used GLT wagon with 57K. Fuctioned nominally (good mpg's, no error codes) The Cat cnvrtr started to rattle for 2k miles or so then error code for the o2 sensor lit up. Replaced the Cat, cleaned the sensors, cleared the codes...BUT...mpg's are down, rotten egg smell coming from mid vehicle, no error codes. (it starts well, no "hunting", idles ok, accerlerates like the pig that it is. My mechanic (good rep & trustworthy)is scratching his ever receding bald noggin with a look of bewilderment.
HELP ME PLEASE!
* What could cause a repeated failure of a cat on a 96 850 nonturbo brick?
* Only the God of Volvo's knows this car's past history ( albeit a clean carfax) but could there be something fundimentally wrong...and how do find out?
* Any and All advice is appreciated.






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