Ford Racing Cat-Back Exhaust System 3" Active Sport Focus RS 2016-2018

Without a doubt, Ford has the best selection of high-performance vehicles from any manufacturer currently out there. They support these vehicles with the Ford Performance line of performance parts. Now, in the case of this kit here, Ford actually went to one of the best in the industry Borla to produce this stainless steel, made in the USA kit to fit your Focus RS. Today, we're going to install it on our 2016 Focus RS.

This Ford Performance by Borla exhaust system is going to fit your 2016 through 2017 Focus RS. This is their active sport system, so we'll work with the factory adjustable exhaust valve, which will plug and play right into this exhaust system. The system's made of 3-inch mandrel-bent 304 stainless steel and features a pair of 4-inch chrome tips with the Ford logo. Like I mentioned before, it's made right here in the USA.

For this installation, a lift or jack and jack stands, 3/8th ratchet, 5/16th socket, 15 millimeter socket, 16 millimeter socket, small flat head screwdriver, and an exhaust hanger removal tool.

Obviously, our RS here has a lot of exhaust systems already installed on it, and it had an aftermarket exhaust that we've already removed. We're gonna give you a quick rundown, though, on how to remove the factory system before we install our Ford Performance.

Through the exhaust, the first thing you want to do is remove the actuator for the active system. Make sure you don't damage it. You can unplug that then unbolt that and put that aside. Now you can remove the exhaust. To do that, like I said, you do have to cut it. What you want to do is go right here in front of the rear axle, right in this section here, we're gonna cut that down the middle. That way we can separate the two pieces and remove the exhaust.

On the first part of the installation, there's going to be this small adaptor piece. This is gonna connect to the downpipe and then to the rest of the exhaust system. This can be a little tricky. You gotta make sure you get it seated properly in the factory clamp, and then make sure this insert in the clamp is in the keyway where it belongs when it's seated. This part can be a little frustrating. Just make sure everything is lined up when it's seated properly. You may have to use a small pry bar or small screwdriver to get it in place. Then we'll tighten it down.

With the extender piece on, now we can install the front part of the mid pipe. This is gonna connect to the factory hangar, so make sure you put a clamp on the front and orientate the clamp so you can get to it, and tighten in down. The mid pipe is actually two pieces. What we're going to do now is do the over axle first. If you get this into place, it makes it easier to put the second part of the mid pipe up. This will be a little tricky. Basically, you want to get it over the axle, and there's a hangar up top that holds it in place.

With a clamp on the front pipe and then on the back pipe, now we can install the second part of the intermediate pipe. Then we'll snug these clamps down; don't tighten them all the way, just get them snug enough to hold the pipe as we'll want to make some adjustments later. The front pipe's installed; now we're ready for the muffler. To put this up, put a clamp on the muffler, connect it to the over axle pipe, and put it up in the factory rear hangars.

Now we're ready to install the control motor. You want to turn this clockwise, you want to make sure that this spring here fits evenly across that. It'll line up pretty decent, you may need a small screwdriver, though, to get it lined up all the way. Then install the nuts and tighten it down.

Now, with that assembled, the last part of the assembly process is to install the tip onto the muffler. We'll snug down the clamp, and then go through and make all of our adjustments. Now the last step is to install the wiring to the exhaust valve control motor. Your installation is finished.

The fit was great, now let's hear how it sounds. We're gonna put it in sport mode to open up the valve. That definitely has a nice tone to it. Not overly loud, but definitely aftermarket. Let's take it for a ride.

The easiest one to compare the Ford Performance to, that I've heard recently, is the ATAK. They're both made by Borla, the installation is very similar. The design is a little bit different, though, this is much, much quieter. If you're looking for a system that ... You got the 3-inch pipes, which larger diameter definitely flows better than the factory system. This has a nice sound driving, but it's not overly loud. I have it in sport mode, so it is with the valve open. When you close the valve, it almost sounds a little bit louder than stock. We figured most of you are going to have the valve open because you’re going to wanna hear it.

Like most of the Borla systems ... The higher the RPM band you go, the sound changes dramatically. Here we are, highway speeds, we're cruising, 2,000 RPM 60 miles per hour, it's quiet. You don't even know it's there. You don't hear it at all, there's no drone, no nothing.

I'll dash it to fourth and get on it. I mean, you definitely hear it, but it's a very ... I don't the word to use, almost like a linear sound. It's definitely not overly loud, it has a good tone, and it kinda keeps that tone throughout the RPM band, it just gets more of it the louder you go, the higher the RPMs you get. This is something we've almost come to expect with a Ford Performance exhaust system. When they build something for the car, most of the time, they take stock up a notch.

It's not ... This is definitely not overly loud. I don't think anyone who's driving this would say, "Ah, this is obnoxious, I can't handle it." This is kinda something that you would say, "You know, Ford can get away with making this in the factory." It'd be a little louder than they normally give, but it's perfectly livable, no drone, no over the top. When you get on it and get off it, you do get that little 'pop' for the exhaust, too. It's kinda become like a signature of the RS.