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Old 04-21-2018, 12:36 PM   #1
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2005 2.0 Exhaust manifold / cat removal.

The flex pipe on my son's Canadian 05 Focus 2.0 is leaking and it looks like it's actually part of the manifold / cat assembly. I want to weld in a new flex section but it looks like I'd have to pull the whole thing out to do it. Before getting started, I'd like to know whats involved, any thoughts?


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Old 04-21-2018, 05:37 PM   #2
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I have no experience with this (especially the Canadian models) but I did have a thought. I "thought" the OEM configuration had the flex pipe assembly as a bolt-on. I just did a search for aftermarket parts, and it seems the flex pipe can be a bolt-on OR can be welded onto the mani-cat assembly.

In your situation, yes, you would have to remove the mani-cat, in order to weld-on a new flex pipe.


Pictures are examples only, not OEM parts.





https://www.amazon.com/Dorman-674-70.../dp/B004AILX5O




and here is a (Walker) manifold that does not have a bolt-on flex pipe
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Old 04-21-2018, 06:41 PM   #3
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Yes, it looks like the California spec setup has a bolt on flex pipe but mine does not. Just wondering if the mani-cat will come out from under the hood with relative ease?
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Old 04-21-2018, 07:25 PM   #4
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I do not know, -I have never done it. I am guessing the mani-cat can only come out via the bottom of the car; least on my car.
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Old 04-21-2018, 07:47 PM   #5
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I do not know, -I have never done it. I am guessing the mani-cat can only come out via the bottom of the car; least on my car.
I hope thats not the case, the gap between the sub frame and the floor doesnt look wide enough to pull the mani-cat through so that would mean dropping the sub frame. Hoping someone can confirm that it will come out the top.
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Old 04-21-2018, 08:33 PM   #6
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Here's an idea-

Cut the flex off of the current exhaust, pull all of it out, weld a flange on the mani-cat, then buy the flex with a flange on it.

You must know how to weld since youre going to weld on this thin of steel, so my idea to me seems easier, quicker and in the future would make the exhaust easier to remove.
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Old 04-21-2018, 09:46 PM   #7
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You can get it out thru the top, thats what I did. I had to remove the evap on the firewall to get the 23 mani/cat out. Mine was a one piece where some are two piece.
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Old 04-21-2018, 10:23 PM   #8
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Great info! Thanks Felix.

I have a sticker on my hood that calls that evap item a "buffer can".

So, your flex pipe was NOT a bolt-on item?
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Old 04-22-2018, 07:43 AM   #9
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Great info! Thanks Felix.

I have a sticker on my hood that calls that evap item a "buffer can".

So, your flex pipe was NOT a bolt-on item?
The oem '05-'07 st's are one piece vs the '03-'04 23's. They look kinda similar to that Walker replacement that you posted. I replaced mine w/ a fwerks header yrs ago. There are a few pic's in my profile album....
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Old 04-23-2018, 08:10 PM   #10
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Thanks for the help guys. I picked up the flex piece today and l plan to put it in on the weekend. The car is a daily commuter so I need it fixed for Monday, thats why I was needing confirmation of the removal procedure, didnt want to run into trouble half way through. I'll update when done.
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