It was a hard job but it's done.

You need to plan ahead and get locking header bolts. $35 to $50 depending where you get them.

You definatley need a lift. You might be able to do it on jack stands but NOT ME, NOT EVER!

You have to remove the right side plastic wheel well. An air conditioner line at the front right side of the engine has to be taken loose ( one bolt ) and temporarily moved. The anti-lock brake wire that attaches to the top of the right upper control arm has to be unplugged and the header slid into place from the top. I will not install from the bottom, transmission and starter are in the way.

The right side of the engine *DOES* need to be jacked up. Remove the *one* bolt in the motor mount. Not too bad to do but you need to know this and plan for it.

You have to have a muffler shop to stretch/spread the inlet pipes on a Bassani X pipe so the mid pipes will slide into them. They are the exact same size.

The rear of the Bassani X pipe has to have two inches cut off of both pipes.

You need a 4 millimeter socket to remove the original studs that hold the cast iron headers on.

You need to remove all sensors before you do anything, being careful not to twist the wires in two. Unplug the wiring first.

The original cat heat shields will not work with the headers, not enough clearance. Remove them. You will still have heat insulation above them. I'm going to try to reinstall them later. Some modification will be required IF it's possible.

A very talented mechanic friend of mine that owns a service station/muffler shop helped me do this job, did most of the work, and it took six hours.

You will need six 1 1/2 inch bolts and locking nuts for the collectors to cat installation. Not nylon locking nuts.

It sounds like a Cobra with Flowmasters but not quite as loud. I'm very pleased with the sound.

As far as performance, I don't know yet. I drove on cats paws coming home because nothing is welded yet. I will be welding the pipes together tomorrow.

Now it's time for a Bud!

 

You and Rusty could write a book--"Headers Are Us" or "Headers For Dummies" .

J/k. Sounds even tougher than changin' the plugs--I'm sure.

Did you get the extended O2 harnesses?

Dan

 

I installed The Kooks headers in my garage on jack stands and I agree, a lift would of been easier but there are some differences with my experience. I did not have to lift the motor at all. I had to disconnect the starter and move the harness to the side. You have to take the inner fender off and the header WILL come through the fender well. You may have to push the heat shield up a tad, but other than that it is straight forward. Also, make sure your tongue is hanging out about one inch.... With a few tongue whirling , you'll have the header in. Make sure you take the studs out first.

Also, before you install the passenger side, make sure to trim the heat shield for the O2 sensor. Before putting the header in place you need to start the lower header bolts and gasket. Screw the bolts about 2-3 turns and slip the header over the bolts.

Everything else went together perfectly. I hope this helps. -Neil

 

Also, make sure your tongue is hanging out about one inch.... With a few tongue whirling , you'll have the header in. Make sure you take the studs out first.

What do you mean?


Dan

 

 

Chickenears,
sounds like a real pita, also it appears that you guys have done an excellent job of documenting the install...only thing missing is the "split knuckle" count and maybe a sound file....JR
drink a couple for me tooo
ps: your sig looks better today

 

Tim - Good write up.

I am going to start mine tommorro night.

I read another post on NLOC that said use a hole saw to cut through the heat shield where the O2 sensors are and its all good from there, thanks for the heads up on the problem with the bassani I would have been PO if I found after everything was on.

Are you guys saying that the BOTH header slide in from the fender wells????

Bob

 

Did you make pictures of your installation? Yours seems easier than mine.

Tell me this: How did you get the right side header into place, in detail if you don't mind? With mine it was impossible to get the header through the area between the front of the transmission and the frame ( going up from the bottom. That led to installing it from the top with wheel well removed and engine jacked up. The header is too wide to fit through the space.

 

No Bob, just the right. The left side will install from the bottom. Be warned, it's not an easy job. If installing spark plugs was hard, I don't know WHAT to call this.

 

Yo Chickenears, my LT header and Hi-flow cat install was a snap. I simply drove my truck to JDM, (1hr.20min. drive) and the pros at JDM performed a perfect instalation that performs like no other and I didn't even bust a knuckle. Just kidding, glad you got it done, now enjoy the fruits of your labor, John H.

 

Geez, sounds fun!! Chickenears, your gallery looks really good man, I like your truck a lot. Glad you got your headers on with ease (jk). So the truck sounds like a cobra with flows you say? :rool:: that's what I'm looking for Especially with the whinefrom the blower, damn, that must sound insane!! Good job, glad you got it done! If possible, can you send me a sound file if you get a chance?

 

That's why I want to drive to NEw Jersey to have them put on by my Tuner, but the wife said we won't have any money for vacation. I told her the Vacation is the Exhaust.

 

Tim you can never make things easy on yourself can you?? LOL

I am glad you got the headers on, I know you are going to love them. Just wait till you really get on it, Hold on man you are goin to be a rockin and rollin.

 

She It! Let's have another Bud!

 

Don's Bolt,

Maybe I need another Bud?