Headers $?%!
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Elder User
Joined: May 2008
Posts: 559
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Headers $?%!
Well, my header re-install is done. What a pain in the ***. 7 studs broken below the surface. One hole was drilled wrong from the factory and couldn't even be helicoiled, requiring me to leave out a bolt. Fortunately it was the #4 cyl and the flange is .400" thick. Sealed up fine. Took 14 hours straight.
So heres the list of what you may need in the future if you purchase ebay headers.
1. Patience, I have none hence why I finished in 1 day.
2. A dewalt 90 degree drill for drilling busted studs.
3. a plethora of cobalt 5/64 drill bits.
4. 4x M10x1.25x60 to replace the too-short collector bolts provided.
5. 14x M8x1.25x40 grade 8.8 bolts for the easy-to-get-ones.
6. 6x M8x1.25x30 grade 8.8 bolts for the bottom center three pipes.
7. 20 spring type lock washers.
8. an old 1/2 wrench cut in half and welded in an L shape for thightening the center bottom 3 bolts.
9. Lots of soap.
BTW, my EGR removal went great, no loss of power I can notice. Diablosport predator can turn off egr switching so that was good. Had to use the fitting from the EGR tube to make a plug for the valve since no-one has the right thread pipe cap.
So heres the list of what you may need in the future if you purchase ebay headers.
1. Patience, I have none hence why I finished in 1 day.
2. A dewalt 90 degree drill for drilling busted studs.
3. a plethora of cobalt 5/64 drill bits.
4. 4x M10x1.25x60 to replace the too-short collector bolts provided.
5. 14x M8x1.25x40 grade 8.8 bolts for the easy-to-get-ones.
6. 6x M8x1.25x30 grade 8.8 bolts for the bottom center three pipes.
7. 20 spring type lock washers.
8. an old 1/2 wrench cut in half and welded in an L shape for thightening the center bottom 3 bolts.
9. Lots of soap.
BTW, my EGR removal went great, no loss of power I can notice. Diablosport predator can turn off egr switching so that was good. Had to use the fitting from the EGR tube to make a plug for the valve since no-one has the right thread pipe cap.
Elder User
Joined: Nov 2007
Posts: 528
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From: Canada, ON New Market
did you notice any loss in mpg sence the mod?
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Elder User
Joined: May 2008
Posts: 559
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No Idea, only driven it about 3 miles so far. I'm taking it round trip to work tonight so 110 miles. I'll post results soon.
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Elder User
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ok, now I got a noise. It doesn't sound like a leak so much but sounds like exhaust rushing through the pipe I had to crease. This thing is driving me crazy at this point. I cut a 2"x12" piece of printer paper and held it around the entire flange and around the collector and didn't detect a leak at all. Truck sounds fine at idle but when you get on it, sounds like a sand blaster is blasting my RH side header. It may just be me though. Krewat: You hear anything like this with yours?
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FTE Leadership Emeritus
Joined: Jul 2002
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From: Long Island USA
Yeah, I kinda get the same type of noise - I chalked it up to header noise. I hear it in both sides.
I notched the frame on the RH side to clear the header, instead of creasing the pipe itself.
I've played around with the y-pipe, and gotten rid of a leak at the collector, and I had a cracked flange just before the cat, and getting rid of all that stuff, it's a lot better, but still have that sand-mixer type noise. Again, chalked it up to header noise.
I was just underneath the other day and re-glued a strip of foam rubber to that bellhousing cover, it was rattling again, and again, quieted it down even more, but still, that noise.
I notched the frame on the RH side to clear the header, instead of creasing the pipe itself.
I've played around with the y-pipe, and gotten rid of a leak at the collector, and I had a cracked flange just before the cat, and getting rid of all that stuff, it's a lot better, but still have that sand-mixer type noise. Again, chalked it up to header noise.
I was just underneath the other day and re-glued a strip of foam rubber to that bellhousing cover, it was rattling again, and again, quieted it down even more, but still, that noise.
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ok, now I got a noise. It doesn't sound like a leak so much but sounds like exhaust rushing through the pipe I had to crease. This thing is driving me crazy at this point. I cut a 2"x12" piece of printer paper and held it around the entire flange and around the collector and didn't detect a leak at all. Truck sounds fine at idle but when you get on it, sounds like a sand blaster is blasting my RH side header. It may just be me though. Krewat: You hear anything like this with yours?
FTE Leadership Emeritus
Joined: Jul 2002
Posts: 42,561
Likes: 420
From: Long Island USA
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 ...