Thinking about replacing the exhaust on a Ford Focus Mk 2 (2004-2010), as we’ve had to do with our 2008 Ford Focus Zetec?
Garage quotes will generally be in a £200-£300 range to replace the whole system, including the catalytic converter. And one reason for this is that the original exhaust system is in one complete part, which connects to the catalytic converter via a short intermediate pipe.
But if you shop around for spares, you’ll find exhaust back boxes and connecting pipes for around £30-£40. So what to do?
The answer, as recommended in some manuals, is to cut the original system to replace the centre or rear silencer. You’ll want to do this mid-way between the centre and rear silencers. As a guide, the cutting point should be around 2033mm from the face of the front flange joint.
And then you secure the replacement part with clamps and rubber blocks, so no welding required.
In practice, you might find it tricky to remove the original system with only one cut and little space to twist and turn, so be prepared to hacksaw through smaller sections to get it out. Obviously we’ve also got quite a small garage.
What you will definitely need is a way to securely get under the car. When you’re using ramps as we were, you’ll want to make sure the car is seated on them, with the handbrake on and in gear if it’s a manual. And then it’s worth ‘chocking’ the wheels with something heavy as well. And if you have other means to keep the car up in case of any problems, then don’t be shy about using them.
It’s a reasonably amount of work, but not rocket science, and will save you a couple of hundred pounds. And if you don’t fancy doing the work yourself, at least you can now find a decent local garage which should be happy to repair just the parts needed – the back box is usually the first part of an exhaust system to go, and the middle section can outlast 2 or 3 replacements depending on your usage and mileage.