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This myFordFocus.com how-to project is sponsored by MagnaFlow Exhaust Systems. MagnaFlow contributed the cat-back exhaust for the myFordFocus.com project car and how-to video series.

Removing the stock cat-back exhaust system is not a terribly difficult job, but there are a few things to watch out for. First, if you don't have access to a mechanic's shop to get the car up on a lift, you will at least want to have four jack stands or some other way of getting the entire car off the ground and safely supported so that you can get under the car and feel safe. Secondly, be sure your replacement system came with all the proper parts, clamps and more importantly a new gasket. Finally, be patient!

Kit Parts: 3 piece exhaust system(front pipe, center pipes and muffler, tail pipe and tip), 2 u-bolt clamps and nuts, exhaust bolts, gasket.

Tools required: 9/16" socket, 11/16" socket(may vary depending on system), hacksaw(or other cutting tool), WD40(or other spray lubricant)

Time to complete: 1/2 to 1 hour

Stock System Removal:

1. Remove your car's battery cables. This will allow your car's computer to reset after installing the exhaust.
2. Lift car.
3. Spray stock exhaust bolts at front assembly with WD40 or other lubricant and let soak to loosen stock bolts. NOTE: If you have alot of trouble with the bolts, heat them up with a torch. Be very careful!
4. Spray all rubber hangers with WD40 or other lubricant to allow system to slide off easily.
5. Using a hacksaw or other cutting tool, cut the stock exhaust pipe in front of rear suspension(see diagram above), to remove rear muffler.
6. Remove rear muffler from rubber hanger. 1
7. Remove rear muffler from under car.
8. Unbolt front exhaust pipe from system(flex pipe). 2
9. Remove existing exhaust pipe from rubber hangers. 3 & 4 & 5
10. Discard stock system.

New System Installation:

1. Assemble center and front section of new system and loosely tighten u-bolts to hold system together.
2. Attach assembled pieces to stock rubber hangers. 3 & 4
3. Place new gasket between new front pipe and stock flex pipe.
4. Using the 9/16" and 11/16" bolt up front pipe to stock flex pipe.
5. Align new sections, and check rubber hangers.
6. Tighten all bolts.
7. Attach new tail pipe to stock rubber hangers 1 & 5 and new center pipe.
8. Loosely attach new u-bolts.
9. Align tail pipe and exhaust tip with bumper.
10. Tighten u-bolts.
11. Double check all bolts and hangers.
12. Lower the car.
13. Attach your batter cables.
14. Start the car and give it a listen! :)
15. If possible, raise the car and make sure there are no leaks.
16. Drive off and have fun!!!

... and now for some before and after photographs. :)

Before	After	Before	After
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Before	After
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