Focus mk1 1.6 exhaust, is this repairable with a sleeve or something?

Pic attached 

 

Is it the centre exhaust silencer? Will it need welding back on or can it be clamped back on?

I doubt it will be able to be welded back on.

The exhaust pipe looks to be too rotten, any attempt to weld it will probably just result it the pipe being burnt away.

There isn't any metal left on the box side to add a sleeve or a clamp.  That just needs replacing.  Probably only around £30 for an aftermarket part.

Would this be the right one I need?

https://ebay.us/m/bIf5Cu

And two clamps required to secure either ends?

 

 

Found a genuine ford one

https://ebay.us/m/Pqzff8

When connecting the new to the old will I need a sleeve? Or will it slot into the old one and secure with a clamp?

29 minutes ago, ash29109 said:

Found a genuine ford one

https://ebay.us/m/Pqzff8

When connecting the new to the old will I need a sleeve? Or will it slot into the old one and secure with a clamp?

Can you show us pictures of the ends on your car?  On some Fords, the whole thing is fitted as one lump before the suspension is fitted.  So needs to be cut and sleeved.  But on a Mk1 it might already have had one replacement.  On that eBay ad it does look like one end of the pipe is flared to slide over another without a sleeve.

35 minutes ago, TomsFocus said:

Can you show us pictures of the ends on your car?  On some Fords, the whole thing is fitted as one lump before the suspension is fitted.  So needs to be cut and sleeved.  But on a Mk1 it might already have had one replacement.  On that eBay ad it does look like one end of the pipe is flared to slide over another without a sleeve.

It's the original exhaust so no clamps in sight 😞

So will need to cut the old one out, the eBay one does look flared so hoping it slips straight it, otherwise will need to purchase a sleeve.

Will require two clamps, any ideas on what size I'll need?

11 hours ago, ash29109 said:

It's the original exhaust so no clamps in sight 😞

So will need to cut the old one out, the eBay one does look flared so hoping it slips straight it, otherwise will need to purchase a sleeve.

Will require two clamps, any ideas on what size I'll need?

Probably 55mm, but I would measure before buying personally.

The Focus MK1/MK1.5 with 1.6 Zetec-SE (Sigma) engine has a 48 mm (outer diameter) exhaust system.

The factory fitted exhaust system on these is a single piece system that is bolted to the exhaust manifold. This single piece contains the catalytic converter, center silencer, back silencer and the connecting pipework.

In case a piece of the exhaust needs to be replaced you have to cut the factory fitted single piece exhaust at the correct position (measure twice, cut once). The replacement exhaust pieces are not flared and have the exact same exhaust diameter as the factory fitted single piece exhaust. 

Ford offers a sleeve kit (you need 2 of these) to connect the exhaust pieces. It is highly recommended to use these kits instead of aftermarket sleeves and clamps because the original sleeve kits makes it much easier to get a leak-free result.


Note that the Motorcraft silencer is marketed as genuine in the Ebay add but Motorcraft parts are actually different from the factory fitted parts. Under the Motorcraft brand name Ford offers a selection of aftermarket parts. These parts are a cheaper alternative to the original Ford Motor Company (FoMoCo) parts.

The original FoMoCo exhaust systems are known to be extremely high quality. They usually last between 10 and 20 Years depending on mileage and environmental conditions (especially road salt during winter). Many of these factory fitted FoMoCo exhaust systems actually survive the rest of the vehicle.

The Motorcraft exhaust parts are not nearly as high quality as the FoMoCo exhaust. Quality wise they can be compared with any other low cost, aftermarket exhaust.


Also be aware that the flexible part of the exhaust manifold is extremely fragile. The flexible part often fails when working on the exhaust system. Especially on a vehicle this age. 

1 hour ago, JW1982 said:

The Focus MK1/MK1.5 with 1.6 Zetec-SE (Sigma) engine has a 48 mm (outer diameter) exhaust system.

The factory fitted exhaust system on these is a single piece system that is bolted to the exhaust manifold. This single piece contains the catalytic converter, center silencer, back silencer and the connecting pipework.

In case a piece of the exhaust needs to be replaced you have to cut the factory fitted single piece exhaust at the correct position (measure twice, cut once). The replacement exhaust pieces are not flared and have the exact same exhaust diameter as the factory fitted single piece exhaust. 

Ford offers a sleeve kit (you need 2 of these) to connect the exhaust pieces. It is highly recommended to use these kits instead of aftermarket sleeves and clamps because the original sleeve kits makes it much easier to get a leak-free result.


Note that the Motorcraft silencer is marketed as genuine in the Ebay add but Motorcraft parts are actually different from the factory fitted parts. Under the Motorcraft brand name Ford offers a selection of aftermarket parts. These parts are a cheaper alternative to the original Ford Motor Company (FoMoCo) parts.

The original FoMoCo exhaust systems are known to be extremely high quality. They usually last between 10 and 20 Years depending on mileage and environmental conditions (especially road salt during winter). Many of these factory fitted FoMoCo exhaust systems actually survive the rest of the vehicle.

The Motorcraft exhaust parts are not nearly as high quality as the FoMoCo exhaust. Quality wise they can be compared with any other low cost, aftermarket exhaust.


Also be aware that the flexible part of the exhaust manifold is extremely fragile. The flexible part often fails when working on the exhaust system. Especially on a vehicle this age. 

 

Thank you for the detailed response, as the exhaust outer diameter pipe is 48mm would I need to purchase a 48mm clamp or should I purchase 50mm clamps?

Do you know the part number for the sleeve kit?

The exhaust pipe outer diameter is listed to be 48 mm.

The sleeves have an inner diameter of 48 mm. The outer diameter depends on the wall thickness of the sleeves.

The clamps should match the outer diameter of the sleeves.


The original exhaust sleeve has Finis number 1854885:





The original sleeve has 3 wave formed compression slots at each end of the sleeve. The wide clamps result in a good compression of the sleeve. My experience is that only a little bit of exhaust paste is needed to obtain a gastight seal between the pipes and the sleeve.
 

In the process of fitting the new exhaust however the rear heat shield above the back box is loose as the fixings have come out of the heat shield.

Searching online, others have completely removed it or fitted oversized washers and nuts to secure it in place 

Would prefer the latter option, does anyone know what size washer and nut would be required?

Or does anyone else have any other suggestions to fix the heat shield 

 

Hack that worked for me.. half a dozen empty drinks cans.. using a pair of scissors cut the bottom off leaving a lip around the sides.. drill a hole in the middle and you have an aluminium washer ready to go.. l spray painted mine and was able to use original screws.. job done.

 

 

6 minutes ago, Focusinford said:

drill a hole in the middle and you have an aluminium washer ready to go

I like that idea, not seen it done before but it's a useful tip 👍

I am quite a fan of the heatshield repair kits that can be found for little money at Ebay, Aliexpress, Temu and similar websites.

I always keep a set of these on stock. When working on cars regularly (especially on older ones) these are really helpful. 

I usually use a bit of polyurethane adhesive to bond the repair washers on top of the heatshield.