Headers $?%!
Freshman User
Joined: Aug 2008
Posts: 40
Likes: 0
From: NJ
Hey guys,
great thread. It really helped having the list of parts. I just took on the task last week. Got you beat on the broken bolts. 5 per side. What a pain, but making progress. I have the driver side mounted. Passenger log is off. Got one bolt out today, the rest tomorrow. Thanks again for sharing your experience with this mod.
great thread. It really helped having the list of parts. I just took on the task last week. Got you beat on the broken bolts. 5 per side. What a pain, but making progress. I have the driver side mounted. Passenger log is off. Got one bolt out today, the rest tomorrow. Thanks again for sharing your experience with this mod.
Hotshot
Joined: Mar 2007
Posts: 10,101
Likes: 40
From: Pa
I wish other people would fix there manifold studs. Seems like everywhere I go lately I'm always hearing a 5.4l and a few 6.8ls tick, tick, ticking away from broken studs. It bugs me, seems many don't know or don't care.
Freshman User
Joined: Aug 2008
Posts: 40
Likes: 0
From: NJ
Many people don't have the knowledge, nor do they seem to want it, much less actually have to buy the tools, get sweaty, and get their finger nails dirty. If its broke, throw it away and buy a new one. Thats a lot easier for those with the bread.
Mountain Pass
Joined: Apr 2008
Posts: 236
Likes: 0
From: Deforest
I bought my truck used. There were three studs broke off on the D/side of my v10 (one exhaust port was leaking). I took it back and made the dealer fix it. Thats what im affraid of, if I try to put headers on my v10. More broken studs.
Hotshot
Joined: Mar 2007
Posts: 10,101
Likes: 40
From: Pa
Time will not make it any better, just more broken studs. My truck had a little over 20k miles on it when I switched to headers. One stud was broken, it just didn't fall off.
Senior User
Joined: Sep 2007
Posts: 445
Likes: 6
From: Montoursville, PA
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 ...
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 ...
Senior User
Joined: Sep 2007
Posts: 445
Likes: 6
From: Montoursville, PA
If you aren't comfortable with it, find a friend who is to give you a hand or else a shop that's willing to do it. At least, if you want to do the headers, it may be a little difficult to find someone willing to do it due to the required notch in the frame. Alternately, you can just drive the thing and let the dealer replace the studs when they break. Your choice, really, I just chose the header route because I figured I'd have some fun and I do just about all my own work.
Freshman User
Joined: Aug 2008
Posts: 40
Likes: 0
From: NJ
VICTORY is (almost) mine! All busted bolts out, no wrecked threads. However, I'm almost broken. I hurt where I've never hurt before. Things look good for getting this buttoned up tomorrow.
I see what you mean about the brake line being too close to the header. What did you end up doing? I was going to get some new line and bend a new one through the frame in front of the header.
Thanks for all the info in these threads. It makes the job quite a bit easier.
I see what you mean about the brake line being too close to the header. What did you end up doing? I was going to get some new line and bend a new one through the frame in front of the header.
Thanks for all the info in these threads. It makes the job quite a bit easier.
FTE Stories
Ford Trucks for Ford Truck Enthusiasts
3 Best / 3 Worst Parts of Modern Ford Ownership
Brett Foote
10 Amazing Upgrades That Solve Common Ford Truck Owner Headaches
Pouria Savadkouei
Every 2026 Ford Engine Explained
Brett Foote
10 Ugly Ford Trucks That We Still Kinda Love
Joe Kucinski
10 Things Every Truck Owner NEEDS (2026 Edition)
Michael S. Palmer
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath
Verdad Gallardo
Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer
Joe Kucinski
2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)
Brett Foote
Top 10 Ford Truck Tragedies
Joe Kucinski
Freshman User
Joined: Aug 2008
Posts: 40
Likes: 0
From: NJ
maybe its different on your truck, but on my Ex, the brake line for the pass. side runs in front , up, then atop the frame to get to that wheel, and with the added width of the headers vs the stock logs, it seems a bit close to that line. I don't want to boil the brake fluid from the heat.
Senior User
Joined: Sep 2007
Posts: 445
Likes: 6
From: Montoursville, PA
I haven't put that line back in place yet, but I don't think there will be any problems there that I'd be worried about. I'll have a look again tomorrow. I just took off the bracket that held it in place to give me better access for getting the header in on that side.
Freshman User
Joined: Aug 2008
Posts: 40
Likes: 0
From: NJ
WooHoo! Headers are on! Sound great open, and no leaks. Just need to attach the Y pipe.
Yea, I'd say brake line is way too close for comfort for me. I think I'm gonna re-route it in front of the shock mount, then cut the L bend shorter so it sits in front at least a few inches away from the header pipe.
Did/do you guys feel safe running sans the inner wheel well? I want to do the same thing. Run to work and back a few times (120 round trip) and check the bolts after each run.
Yea, I'd say brake line is way too close for comfort for me. I think I'm gonna re-route it in front of the shock mount, then cut the L bend shorter so it sits in front at least a few inches away from the header pipe.
Did/do you guys feel safe running sans the inner wheel well? I want to do the same thing. Run to work and back a few times (120 round trip) and check the bolts after each run.
Senior User
Joined: Sep 2007
Posts: 445
Likes: 6
From: Montoursville, PA
I wouldn't worry about the brake line, especially while driving where there's enough air to keep everything cool... but that's my personal comfort level. If you want to change it, by all means. 
I'm planning on running without the inner wheel well until everything settles. Check everything and zip strap back as required to make sure that things don't hit the wheel. In my case, there were two wires I zipped back and then also the I think vacuum reservoir that sits on top of the passenger side fender well. Looking at your truck for a bit should show you want you need to do.
I would keep this as a temporary thing and try not to drive in the rain or mud like this (after all, that's what those things are there to protect against), but that's just me.
I'm planning on running without the inner wheel well until everything settles. Check everything and zip strap back as required to make sure that things don't hit the wheel. In my case, there were two wires I zipped back and then also the I think vacuum reservoir that sits on top of the passenger side fender well. Looking at your truck for a bit should show you want you need to do.
I would keep this as a temporary thing and try not to drive in the rain or mud like this (after all, that's what those things are there to protect against), but that's just me.
Freshman User
Joined: Aug 2008
Posts: 40
Likes: 0
From: NJ
No doubt. I will not be driving in the rain without the inner well. Water and electricity don't mix very well.
Having a time with the Y pipe today. Not quite a perfect fit. I'm having a friend come by tonight to lend a hand.
I'll tell ya, that brake line, when put back in its place is only mm's away from the header pipe. Not cool....(no pun intended)
Having a time with the Y pipe today. Not quite a perfect fit. I'm having a friend come by tonight to lend a hand.
I'll tell ya, that brake line, when put back in its place is only mm's away from the header pipe. Not cool....(no pun intended)
FTE Leadership Emeritus
Joined: Jul 2002
Posts: 42,561
Likes: 423
From: Long Island USA
Yeah, the y-pipe on mine had to be bent slightly to get it to fit.
If I had it to do over again, I probably would have cut the left pipe where it's straight and put in a coupler.
If I had it to do over again, I probably would have cut the left pipe where it's straight and put in a coupler.