I have not installed headers on a 4wd drive before. My Question is is this to close to the front drive line? If so and you had this problem what was your cure? Im thinking cut the collector and put a 45 degree bend with the flange away from the drive shaft.

 

Way too close.....Your idea to cut it and put a 45 in there is probably as good an idea as any.

 

I was afraid thats what I was going to hear. Da*n at least Im not hurt to bad. The headers were only about $165 from Jegs not including shipping. Have to see if the exhaust shop guy can rescue me. If not any suggestions Im open at this point.

 

How close are they near the 4-1 merge? Might be ok with cutting off the collectors and having the exhaust shop make new pipe coming from the merge, and use a more conventional (and thicker) flange. That would reduce the possibility of the collector gaskets causing leak issues...... One of my main pet-peeves with most headers, cheap collector flanges that repeatedly leak, due to flexing/bending.

 

That could be a plan Ill talk about that with the exhaust guy if he is stumped. Thanks for the heads up R_W.