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What would cause an almost new catalytic converter to go bad? 700 1991

Hi,

I have a 91 745 GL non turbo 8v and about a year ago I replaced the mufflers, and catyltic converter at about 135K(The catylic converter had been making a lot of noise). Now it is a year later and about a month ago it started making the same noise especially when shifting from 1-2 and 2-3 just like before. I checked the computer and their are no error codes. Is the catalytic converter(its a Bosal) just defective or could there be something else wrong with the car? The car was in for service from the Volvo dealer at 125K and 130K and the car runs very well.

The place I bought the converter from wants me to return it. Since this is my only car I can't just live without a car with no exhaust(especially since I'm in the process of relocating to North Carolina where they do a smog test and I don't know if it will pass the test with this problem) I don't know what I should do about it?

Thanks for your help

Mike






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