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Definitely get new sleeves. They seem to conform to the unique profiles of each muffler/cat union and it is a cheap and quick test.
The cats could be the culprit. I think there is a reason that they are only warrantied for 1 year and only to the original owner.
I bet AWE would check them out for you and possibly replace the elements if necessary. They have an even newer HJS section now that has a new type of coating that is more efficient.
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dr
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