Well, my header re-install is done. What a pain in the ***. 7 studs broken below the surface. One hole was drilled wrong from the factory and couldn't even be helicoiled, requiring me to leave out a bolt. Fortunately it was the #4 cyl and the flange is .400" thick. Sealed up fine. Took 14 hours straight.

So heres the list of what you may need in the future if you purchase ebay headers.

1. Patience, I have none hence why I finished in 1 day.

2. A dewalt 90 degree drill for drilling busted studs.

3. a plethora of cobalt 5/64 drill bits.

4. 4x M10x1.25x60 to replace the too-short collector bolts provided.

5. 14x M8x1.25x40 grade 8.8 bolts for the easy-to-get-ones.

6. 6x M8x1.25x30 grade 8.8 bolts for the bottom center three pipes.

7. 20 spring type lock washers.

8. an old 1/2 wrench cut in half and welded in an L shape for thightening the center bottom 3 bolts.

9. Lots of soap.

BTW, my EGR removal went great, no loss of power I can notice. Diablosport predator can turn off egr switching so that was good. Had to use the fitting from the EGR tube to make a plug for the valve since no-one has the right thread pipe cap.

 

did you notice any loss in mpg sence the mod?

 

Rep points to you Heavy_Metal!

I like posts that outline everything needed to do a mod.

 

No Idea, only driven it about 3 miles so far. I'm taking it round trip to work tonight so 110 miles. I'll post results soon.

 

Great report, rep points given...

Sounds like my little trip down frustration lane. And the wrench too

 

I also had to dent one primary pipe on the RH side pretty good to get it to fit.

 

ok, now I got a noise. It doesn't sound like a leak so much but sounds like exhaust rushing through the pipe I had to crease. This thing is driving me crazy at this point. I cut a 2"x12" piece of printer paper and held it around the entire flange and around the collector and didn't detect a leak at all. Truck sounds fine at idle but when you get on it, sounds like a sand blaster is blasting my RH side header. It may just be me though. Krewat: You hear anything like this with yours?

 

Yeah, I kinda get the same type of noise - I chalked it up to header noise. I hear it in both sides.

I notched the frame on the RH side to clear the header, instead of creasing the pipe itself.

I've played around with the y-pipe, and gotten rid of a leak at the collector, and I had a cracked flange just before the cat, and getting rid of all that stuff, it's a lot better, but still have that sand-mixer type noise. Again, chalked it up to header noise.

I was just underneath the other day and re-glued a strip of foam rubber to that bellhousing cover, it was rattling again, and again, quieted it down even more, but still, that noise.

 

I got the same noise on my 05 3V with JBA headers. No leak but same type sound. No milage increase for me at all, power increase? Hard to tell with that big of a truck and the better 05+ stock manifolds.

 

nice write up
i should be doing this within the next few weeks so it is good to know what neds to be done thanks

 

H M - thanx for the good info!

 

Just noticed on ebay, no more V10 headers....... Guess I'm glad I got them when I did.

 

After 120 miles, pulling a 6800 TT I averaged 8.2mpg with the egr off and headers along with the mods in my sig.

 

Actually, that cement mixer sound, I don't know why I said I get it in both sides - I get it mostly on the passenger side, it's obvious when passing a wall on the passenger side, but nothing from the driver's side.

The more I think about it, it did it BEFORE the headers. I wonder if it's just exhaust noise out the tailpipe? Gotta really get into it more ...

 

I haven't really gotten enough mileage on mine to suspect a leak. If anything, I would believe it to be the collector since I had such a hard time lining both sides up.