AWE 3025-32024 SwitchPath Cat Back Exhaust for Ford Focus RS Installation Guide

: June 12, 2024
: AWE

AWE 3025-32024 SwitchPath Cat Back Exhaust for Ford Focus RS Installation

Guide

THIS GUIDE IS INTENDED FOR THE FOLLOWING PART NUMBERS:

3025-32024| AWE SwitchPath™ Cat-back Exhaust (with Remote) for Ford Focus RS – Chrome Silver Tips
3025-33024| AWE SwitchPath™ Cat-back Exhaust (with Remote) for Ford Focus RS – Diamond Black Tips

Welcome to the AWE family, and congratulations on your purchase of the AWE Exhaust System for the Ford Focus RS.
Exquisite build quality and craftsmanship, coupled with industry leading performance, distinguish this exhaust system from all others.
*For up to the minute fitment information, be sure to visit the AWE website. As always, AWE Performance Specialists are standing by for any questions, right here.

PARTS LIST

Inspect ALL parts prior to disassembly of vehicle; If damaged or MISSING, please contact the place of purchase immediately.

Part Number	Description	QTY
YD	Focus RS NON-Resonated Front Section	1
YE	Focus RS Mid Pipe	1
YG	Focus RS Switch Path Over-Axle Pipe	1
YH	Focus RS Switch Path Muffler	1
YI	Focus RS Switch Path DS NON Valve Outlet Tube	1
YJ	Focus RS Switch Path PS Valve Outlet Tube	1
390225	2.25 Inch SS Smart Seal Band Clamp	1
180300	AWE Band Clamp: 3″	5
1325-11012	AWE SwitchPath Remote Control Box

Tip Options
| 61000078| 4.50″ OD x 3.00″ ID, Slash Cut, Chrome Silver, AWE Logo| 2
| BHM8X079SS00C| Barrel Hardware Clamp – All 300 Stainless Steel 2.91″ – 3.11″| 2
or
| 180015| YELLOW 4.50″ OD x 3.00″ ID, Slash Cut, Diamond Black, AWE Logo, Integrated Clamp| 2
| 3910-41010| Hardware Kit for Integrated Clamp Style Exhaust Tips| 1

STEP 1

The factory exhaust must be CUT from the car to install the AWE Performance Exhaust System. Reinstalling the factory exhaust will require the use of a sleeve clamp that is not included.
Always refer to the manufacturer service manual for precise torque specifications on all OEM fasteners. With engine off, unplug the wiring harnesses from the valve actuation motor, shown at the arrow in Figure 1

NOTE: If the factory controller will be operating the exhaust valve on the AWE SwitchPath™ system; it will be necessary to swap the factory motor onto the new exhaust system, as shown in Figure 1

STEP 2

WARNING: If floor jacks are being used, instead of a lift, it may be difficult to remove and/or install the components that go through the rear axle area. DO NOT exceed the limitations of floor jacks and jack stands.
To remove the factory exhaust, locate the bend as shown by the arrow in Figure 2-1.
Measure 2” up from the point shown by the arrow in Figure 2-2 ; the arrow marks the end of the bend. Using masking tape can be a helpful aid in make a straight cut with a metal cutting saw.

STEP 3

Support the rear muffler assembly so the hanger bushings can be removed from the posts.
Pull the bushing away from the post, shown by the arrow in Figure 3.

Remove the rear section from the car

STEP4

Loosen the factory V-band clamp so the remainder of the exhaust can be removed.
Transfer the factory V-band to the non-resonated front section (part YD ), and install as shown by the arrow in Figure 4.
Do not torque the factory V-band clamp until Step 10.

STEP5

Install the over-axle tube (part YG ) using one of the included 3.0” Accu- Seal clamps. Orient the clamp away from the heat shielding, as shown by the arrow in Figure 6.

STEP 6

Remove the bushings from the hangers on the car and preinstall them onto the SwitchPath™ muffler section to make installation easier. Install the SwitchPath™ muffler (part YH ) with a 3.0”
Accu-Seal Clamp. Fully seat the pipe and insert each hanger into the appropriate hanger bushing. Each hanger bushing should be slightly forward in- car, as shown by the arrow in Figure 7.

STEP 7

Install the driver side tailpipe (part YI ) onto the SwitchPath™ muffler outlet using the included 2.25” Accu-Seal clamp, as shown Arrow A in Figure 8.Install the passenger side valved tailpipe (part YJ ) onto the SwitchPath™ muffler outlet using the included 3.0” Accu-Seal clamp, as shown Arrow B in Figure 8.

STEP 8

It is crucial to install each section and Accu-Seal clamp correctly to prevent loose joints and exhaust leaks between the tubing connections.
Arrow A in Figure 9 shows the expanded pipe and the preinstalled Accu-Seal clamp being brought up to the corresponding pipe.
Arrow B in Figure 9 shows the overlapping pipe installed correctly over the corresponding pipe.
Arrow C in Figure 9 shows the Accu-Seal clamp being brought to the edge of the expanded pipe.

NOTES:

Do not torque any Accu-Seal clamp until the entire exhaust has been installed and Torque specification is a minimum of 40 ft/lbs

STEP 9

Install each exhaust tip with an included tip clamp, but do not torque until the exhaust system has been fully adjusted and tip placement is satisfactory.
With the entire exhaust system aligned, and each clamp positioned away from the chassis to avoid any rattles, tighten and check all hardware to complete the installation.
Figure 10 shows where to start and finish.
Torque the V-band clamp to the factory specification. Torque the Accu-Seal clamps to a minimum of 40 ft./lbs.

STEP 11 A

To install the exhaust tips with integrated clamps, first, attach the exhaust tip in the proper orientation onto the exhaust outlet tube.
Insert one of the carriage bolts from the hardware kit (3910-41010) through the tab on the exhaust tip and thread on one of the corresponding nuts.
Using anti-seize on the bolt threads will help installation and prevent breakage of hardware.
This exhaust system only has 2 exhaust tips while the integrated clamp kit has enough hardware for our 4 tip exhaust systems. You will have 2 sets of hardware left over that will not be used.

STEP 11 B

For the best tip fitment, align the barrel style tip clamp to cover only the slot, shown by Arrow A
Torque the tip clamp to 18 ft./lbs.

NOTES:

It is required to apply anti-seize to the threads to prevent thread binding, shown by Arrow B
It is okay to have the clamp extend beyond the edge of the tip

STEP 11

This step applies to both the SwitchPath™ Remote kit and the extension harness.
Locate the factory harness from the valve control motor, as shown by Arrow A in Figure 11-1.
Connect the female end of the supplied AWE Extension Harness or SwitchPath™ control box harness, shown by Arrow B in Figure 11-2 , to the male end of the factory harness.
NOTE: If upgrading to the AWE SwitchPath™ controller, please install the motor that was originally supplied with the exhaust.

STEP 13

Route the new AWE Harness Extension or the optional SwitchPath™ control box harness up and behind the heat shielding in the rear bumper skin area, as shown by the arrow in Figure 13.
Plug into the new valve located on the passenger side tailpipe.
NOTE: If the SwitchPath™ control box has been installed, turn the vehicle on without starting the car and cycle the valve to “On” & “Off” to ensure proper operation.

TROUBLESHOOTING

Issue	Solution
Exhaust is not fitting correctly	Most fitment issues are due to improperly

adjusted exhaust. This includes tip fitments and rattling due to chassis contact. Check out our fitment guide for more installation tips.
Incorrect or missing parts| Double check the parts list for your system and compare them with what you received. Fill out our contact form, found below and let us know what parts you need.

CARE

Once installed properly, your AWE exhaust will provide years of trouble-free performance.
The exhaust volume and sound will settle with usage; 800-1000 miles is required to break-in new exhaust systems.
Also, please note that the rear 180Technology® resonator has a small drain hole to allow condensation to escape. Water drops from this area are normal. Periodic cleaning of exhaust tips is necessary to maintain proper finish, especially in areas prone to road salt and caustic deicing solutions. Use a mild soap and water solution or car wax to clean the finish. Avoid using abrasive polishes, as they can scratch the finish.

Any questions or comments,
please do not hesitate to contact us:

AWE

215-658-1670 CONTACT FORM