Header Install Tips
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Elder User
Joined: Mar 2003
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From: Medford, OR
Interesting...seems my signature is gone for some reason. It is a 93. If not for that bolt shearing off and the mix up with the crossed wires and cracked plug, it would have been a leisurely weekend job. Those were the biggest pains. 1-10 I would say it was a 7 as it was, and could have been a 3 if not for the things mentioned.
Last edited by Wakeboarder141; Mar 24, 2004 at 12:08 AM.
Senior User
Joined: Nov 2003
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From: Camden County, NC
I saw your gallery, nice rig....I am still cautious about my manifold bolts because of the rust and grime. Mine beast did not come from from Fla. Your pics look like the engine compartment was ALOT cleaner than mine. I do not feel like getting into heads at this point....any ways again nice rig.....
Super Moderator
Joined: Oct 2002
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From: MA
Originally posted by Wakeboarder141
I didn't use any kind of penetrant. They were all hard enough to need a long breaker bar to turn them almost the whole way out.
I didn't use any kind of penetrant. They were all hard enough to need a long breaker bar to turn them almost the whole way out.
Rich
Senior User
Joined: Nov 2003
Posts: 258
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From: Camden County, NC
What are the odds that if I soak/treat the bolts for a couple days that I still break one? Even with a soft touch and not rushing. I know this is a hard ? to answer but I need some feedback. I would rather pull my own tooth with a pair a vice grips than go into the heads anytime soon. The rust is more than enough for a 93 model. I have heard answers across the board from people I 've talked to. "No problem....piece of cake... all the way to I would never do it again....If it ain't broke don't fix it..."...Thanks....
Senior User
Joined: Nov 2003
Posts: 258
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From: Camden County, NC
What are the odds that if I soak/treat the bolts for a couple days that I still break one? Even with a soft touch and not rushing. I know this is a hard ? to answer but I need some feedback. I would rather pull my own tooth with a pair a vice grips than go into the heads anytime soon. The rust is more than enough for a 93 model. I have heard answers across the board from people I 've talked to. "No problem....piece of cake... all the way to I would never do it again....If it ain't broke don't fix it..."...Thanks....
Super Moderator
Joined: Oct 2002
Posts: 8,547
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From: MA
Even with multiple penetrating days, they can still break. The metal is exposed to both extremes of fatigue (rapid heating and cooling) through countless cycles (each time you've driven youre truck). Soaking helps, but it is by no means a sure-fire solution.
Rich
Rich
Fleet Mechanic
Joined: Aug 2002
Posts: 1,568
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From: Swansea SC
header night mares
After reading this thread -i do remember the pain i had in changing the header gaskets( leak) Used pb blaster, kroil along with other penetrants with no luck Seems my day job turned into a two weekend job. After breaking two studs-----redrilling them out would i tackle this project again------ glad ya got it wake board -- 
i feel it makes u appreciate your truck more after the pains we partake especially the cussin ones----TR 
i feel it makes u appreciate your truck more after the pains we partake especially the cussin ones----TR
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Senior User
Joined: Mar 2004
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From: New York
I know it was a pain when I did my headers. Used pb blaster and for those stubborn bolts I used a acetylene torch. Best header bolts to get is the locking ones made by Stage 8.
Wake board, you may want to check out a helicoil. That's a threaded insert for replacing the damaged threads or in your case a broken bolt. Good luck.
Warr
Wake board, you may want to check out a helicoil. That's a threaded insert for replacing the damaged threads or in your case a broken bolt. Good luck.
Warr
Posting Guru
Joined: Dec 2003
Posts: 1,483
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From: Northern California
Yeah, the stage 8 are definitly the way to go...I suggested these back at the beggining of this thread, did you use these bolts wakeboarder? They will keep you from having issues with leakey headers. This is cheap insurance against future issues with your new headers!
Senior User
Joined: Mar 2004
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From: New York
I definitely agree with 94F150-408 on the stage 8 suggestion. I used the bolts that came with my bbk headers and that was the worst thing I ever did. The bolts came loose and the gasket blew apart. I've replaced them with stage 8 and earl's header seals. No more problems!!!
Warr
Warr
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Elder User
Joined: Mar 2003
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From: Medford, OR
I used the bolts that came with the headers. I plan on doing a full rebuild, maybe a stroker, along with replacing the heads before too long. Since they are already in do you think they will be ok until then? Since they have been installed, I have only had one complaint. I haven't retorqued the bolts, but I don't know if that is what is causing this. At certain RPM I have sort of a thunking. It is fast paced, like a slow machine gun. Almost sounds like when a CV joint is bad and you are turning. It does it when I am going straight though, and only at certain RPM. Does that sound like it could be an exhaust leak because of that missing bolt? Thanks.
Senior User
Joined: Mar 2004
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From: New York
Definitely and you probably blew the gasket too. My truck made the same noises when one of the header bolt loosened up. You'll want to get that broken bolt out to cure the problem and yes you need to retorque the bolts if your not going to use a locking set-up.
Warr
Warr
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Elder User
Joined: Mar 2003
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From: Medford, OR
If I go with those locking bolts, are they reusable? Or will I have to replace them when I decide to change the heads 6 months or a year from now? $55 seems a little steep if they aren't going to last me for quite a while. The gaskets that came with my headers are metal with graphite inserts. If they are blown out would I just need to replace the graphite inserts? Thanks.