I'm installing BBK ceramic headers on my 94 5.8. Generally I'm pleased with the quality of the header itself. But I have couple of issues:

- the 3/8-16 x 3/4 bolts they send are NOT long enough. the threads in the head are .8 in deep and I like to have a good 1/2 in of threads into the head for a secure hold. I solved this by buying the Stage 8 locking bolts in the 1" long version.

- there are NO instructions or hardware for the 3 places you need a double-ended stud: oil dipstick bracket, support bracket for ign coil, and on the RH side, support bracket for the upr intake manifold. I guess your just supposed to figure this out for your self. Solution for me was to buy some 2" studs from napa and then make my own spacer for the upr intake manifold support bracket (see photos)

- now for my problem, has anyone had galling issues installing the EGR adapter coupler into the RH header. it goes in for about 2 threads, gets real tight and starts galling. I've checked the pitch of the threads on the header and on the coupler. they seem to be the same pitch. the coupler came with the new EGR tube from Ford. So I believe it to be right.

Thoughts anyone?

Thanks!

 

I had BBKs on mine and they did not bolt up to my Y pipe and leaked like a ****. Sent them back and got some Ford Motorsport shortie headers and have had good luck with them.

I also had a hard time getting my fitting to screw on to the header EGR tube,befor I sent the headers back I went to take my fitting off and broke the tube right off the header,that didnt make me to happy,lol.

 

wow. the welds must have been shoddy. though on mine they LOOK great, course I'm not an expert on the integrity of welds either. I'll be hooking mine up to a Basani Y-pipe.
I held the y-pipe up to the headers while the engine is on the stand. the y pipe seems to mate up with the BBK's ok. the proof will be once the engine is installed. What Y pipe were you using and did you use a gasket of any kind between the header and the y pipe?

thanks for the input.

Kind Regards,

 

I was using my factory Y pipe setup,I used percys dead soft aluminum blow proof gaskets on the headers. 50,000 miles and still no leaks. My BBKs just leaked were it hooked to the Y pipe because the alignment was way off. The weld looked good on my EGR tube but my fitting was stuck in there so tight it broke it anyways,I dont think the threads were tapped right from BBK.