OK, no total resolution yet but I do have to say that dealing with Eastern has been good. Very prompt at responding and they too are perplexed. Car is going to a dealer tomorrow night (friend of mine is Service Director at a BMW - Toyota dealer). We're going to put car up on lift to check cats again for physical damage and also to check computer for any codes. Eastern is telling me that pretty much it would have to be an overrich condition or misfires to cause cat damage. There are no codes showing in system now.

Any one have any specific ideas on how to check performance for either a faulty injector or misfire that might not trigger codes ??

I'll keep the forum up to date as I find somethin out.

Eastern has asked if the front cats are original. I'm not sure just why they might affect the rears as I understand most of the problems with the 540's are the rear ones.