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Ok, just yanked a set of full length headers off my new to me 1996 Bronco 302 - they dumped out mid transmission and a Y pipe would've hung below that...
Getting those reduced head bolts out was a pain for cylinders 6&7, is there any reason I couldn't use a longer bolt with a steel sleeve? Dodge is famous for doing this. Just checking my math before I do it.
That might be something known in the MOPAR world. I wouldn’t know because I haven’t worked at the Chrysler dealer since 2004. The style of bolt you use makes all the difference. I think the last time I used 12 point locking bolts. A chrome socket is thin enough to get in there to tighten it. Are you installing shorty headers or OEM style manifolds? It might not be an issue anymore.
I have 5/16th ARP 12pt head bolts and they are a pain to keep tight.
If you got room, there is no reason you can't use a stud/bolt and a sleeve. I plan on building a long tube header for my 408 project and I plan on drilling my heads to a wider bolt spacing. Focusing on easy of installation.
Putting some old Pace Setter short tube headers (stock manifold replacements) allowing a factory non Cat (1983?) F350 Y Pipe into a 3" single exhaust down the passenger side. Bolts I took out were reduced head (3/8" hex) and the chrome 1/4" drive socket was too thick for 2 of the driver's side bolts - going to work on passenger side tonight. Ignition wrenches would've been helpful but my son says he didn't use them and doesn't know where they are... For the RH bolt on #6 I ended up dinging the tube inward with a chisel to get the ground down socket onto it! At least Frieberger and EngineMasters showed that dented headers don't hugely effect exhaust flow!
My newish long tube Pace Setter with standard small header bolts fit perfectly, 351w, no issues with sockets on any of the bolts. 1"7/8" primaries I believe.
I suspect not, but when I look under the hood of any car/truck, those dents would clearly show up. Ruins the entire look of a nice engine.
I have never had an issue with the 5/16 12pt ARP bolts and with a Snap On wrench, it just works. A Snap On 8mm is slightly smaller and grabs on the bolt that much better. The tough part is getting enough leverage to tighten it up so they don't loosen during heat cycles.