I must say, I'm quite satisfied with the end product. Noticable improvement in flow, and it smoothed out the rest of the exhaust. With the factory manifolds, it vibrated a lot; especially between 2500-3000rpm. The headers smoothed it out, and I think it actually made it a bit quieter.
If I had to do it over again, I'd save some money and pay someone to do it. Never in my life have I come across a more tedious, pain-staking task. I have (literally) dropped and replaced an entire transmission with clutch and all in less time than it took me to put those headers in. We had to remove the starter, a leg of the sterring column, both motor mounts, the h-pipe, and we still had to cut some pieces the drivers side header to fit around the oil dip-stick and on the passengers sid header cut a piece out to allow one of the bolts to fit through. 12 hours, 4 trips to the auto parts store, and a few gallons of sweat and blood later, my buddy and I finished with no exhaust leaks or clearance issues.
If you plan on doing this yourself, think twice. I had to take the day off of work today because I feel like a 1000 year old fossil right now. My hands feel like I have severe arthritis, and the rest of my body feels like it was hit by a truck. A lift would make this job MUCH easier.....we have power tools and that helped for very little. There is no clearance to do anything; I had to get my girl to use her tiny hands to get some of the header bolts going before I can tighten them. The ones to the back nearest the firewall are damn near impossble to get to.
I'd rather bellow-flop naked on a poisonous cactus patch full of angry fire ants before doing that again.
The headers I bought on eBay.....I'm not sure who makes them, but they are ceramic coated shorties. I tried the car out, and I did notice a gain; I'd say between 6-10 hp. The major improvement is in how smooth the exhaust flows out of the car now. Before, I would take my phone out of my pocket thinking it was vibrating, but it was the the car. Now, it just flows and you hear the exhaust, but you don't feel it rumbling inside the car so much. I approve.....I'm a gearhead and all, but good stuff all around.
As far as the tune goes, the car is running fine. I have a Diablo tuner, but it is the special Steeda version that comes with Steeda tunes calibrated for Steeda parts. It has a tune for the CAI, and one forthe CAI and CMCV plates. I don't have the plates, so I only have the CAI tune, but it runs just fine. Idles rough when I start it cold, but once it gets some temp, she's good to go.
As far you or anyone knows, do headers require a tune? I was under the impression they didn't.............
Now your scaring us!! All that blood sweet and tears. Dont forget to retorque everything after a few heat cycles. or are you to busy bellyfloppin..... Hope you enjoy them. Good story.
Hahahaha......yea, I'm not looking forward to re-checking the bolts. Although now that they are in place, all I have to do is check them with the set of ratchet wrenches I bought (one of the best tool inventions EVER!) and it shouldn't be that bad.
I am happy to say that after a few days, the car "learned" to deal with the headers and the idle fluctuation completely is completely gone. The headers made the flow smoother and a feel a slight gain in hp. Car is running great, and I'm quite satisfied. \It was worth it.......
I started my install earlier today and I just stopped for the day. Needless to say I didn't get very far, this has to be one the largest pita I've ever attempted. I unbolted the steering shaft but I can't get it apart to take it out. I can't get to the oxygen sensor on top of the transmission to unplug it nor can I get to the top bolt on the starter to take it out. I took the bolts off the motor mounts that attach it the K member but when I attempted to lift the motor to gin better access to the bolts attaching them to the motor the entire front of the car raises up. I've read the instructions from BBK and I've printed the article from Mustang Monthly. I'm frustrated to say the least. Any self installers got any pointers that might help me along?
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2006 Black Roush Stage 1, Roush CAI, Eibach pro-kit, adjustable panhard bar, SCT X-cal 3w/Bama tunes, BBK shorty headers and off-road h-pipe.
Ok, first the steering column. There are two bolts that need to come off for the install: You need to remove the leg that goes from the firewall to the rack-and-pinion; this will require the steering wheel to be turned so you can access one bolt from the engine bay using long extensions and the other from under the car. With this out of the way, the driver side header is good to go (I was able to remove the stock header on this side without lifting the engine, but the passenger side did not come out without me removing the entire motor mount bracket off of the car and the engine).
I know what you mean about the front end of the car lifting when you try to lift the engine, but you will not be able to gain any clearance until all bolts are removed from the motor mounts. You have to remove the one large bolt that holds the bracket to the car, and each of the 3 bolts that attach the bracket to the engine. Place a floor jack under the oil pan and leave it exatcly in place to when all bolts are removed, you can jack it up. Leave the engine hanging in the air with the floor jack (I used two pieces of 2x4's under the oil pan when I jacked mine up) and loosen all the factory header bolts. Once the header is completely loose, you will be able to unplug the oxygen senson with the extra clearance.
I HIGHLY recommend you go out and get a ratchet wrench for the header bolts. If you think loosening the header bolts is tough, wait until you try to put the other headers on with the larger runners; you'll have even less space to work with.
As far as the top bolt on the starter, I got to it using a small 1/4" ratchet and a long socket. Feel for it with your hands over the top of the starter and put the socket over it. You will have little clearance to swing the ratchet, so it's going to take a bit to unscrew and screw that one bolt.
I am giving you this info providing your car is a stick like mine. If you have an auto, your transmission may be larger or you have to do something I didn't. It took my friend and I 12 hours, and we have a lot of tools and we are both mechanically inclined. GOOD LUCK!!!!! I would NEVER do it again after what I went through..........
I'm too far into it to pay a shop to do it, besides the car is undriveable at this point. I'm very mechanically inclined so I'm sure I can do it, I've installed several sets of headers in the past just not on this body style. I took the bolts out of the steering shaft but I still can't get it out. There is up and down play in it but not enough to pull it apart.
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2006 Black Roush Stage 1, Roush CAI, Eibach pro-kit, adjustable panhard bar, SCT X-cal 3w/Bama tunes, BBK shorty headers and off-road h-pipe.
The steering column shaft should come out if you removed the top and bottom bolt; I remember one being longer than the other one. Get a long flat-head screwdrivver, and the piece of metal that comes out of the firewall and into that shaft can be pushed into the firewall so the shaft falls out. Once you do that, you can push it back out to the engine bay from under the dash when you're ready to put it back on. You will need someone to help you by turning the steering wheel to give you access to re-tighten the bolts.
You still a long ways to go, my friend! Good luck!
I figured it out, I had taken out the wrong bolt. Once I had the right one out the shaft came right out. I got the drivers side manifold unbolted so I'm making headway. I'm not under any time restraints so however long it takes. That's why I built the garage workshop so I could work on my toys at my leisure.
Thanks Joe
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2006 Black Roush Stage 1, Roush CAI, Eibach pro-kit, adjustable panhard bar, SCT X-cal 3w/Bama tunes, BBK shorty headers and off-road h-pipe.
Oh, ok.....good stuff. I'm at work in front of the computer for a while, so feel free to holler if you get stuck. The higher up you can get the car off of the floor, the easier it will make this job. Again, if you don't have them already......I HIGHLY suggest getting a ratchet-wrench for the header bolts.
+1 on the install......I had three mechanics at my local shop install my JBA Shorties for me as a favor. One of them worked at a Midas Muffler Shop for three years. After they had the car for 3 or 4 hours I went to see how it was going.......they looked like this when I got there When you read the box it sounds easy....direct bolt-on replacement of stock exhaust manifold..........Yeah Right!!!!
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"A man's gotta know his limitations"...Clint Eastwood
Posts: 147
Joined: 9/10/2007 From: Fredericksburg, Virginia Status: offline
quote:
ORIGINAL: Yonco This sounds to fun to pass up, Imma get my headers sooner than later just so i can take a crack at this "challenge" -Jon
You will have "fun" doing it. I did my intall in my driveway with just regular tools, ramps, and a floor jack (to raise the engine) in just over 7 hours. And that was taking my time and enjoying a few brewskis.
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06 GT Vista Blue 64Ws Manual Sequentials 50F/35R Metallic Tint K&N Drop-in Air Filter JBA Shorty Headers JBA Exhaust BamaChips 87 Octane Tune
I would call it anything but fun. I threw down a few beers myself; it was the only thing keeping me from going insane and just turning my car into a huge mushroom cloud. I was ready to give up; my buddy is the one that kept me going to finish in one day. Not to mention, he has a permanent scar on his left cheek from a wrench falling on his face while under my car trying to do this. He needed stitches and all! (of course, he didn''t get them, because we''re all macho men )
It can be done (obviously), but I''d hardly call it fun. Biggest PITA I''ve encountered in a long minute.
I took a weekend to do mine. Yeah, it was a PITA. I blead, sweat, drank, swore, swore, swote, and blead some more, but in the end...I''d do it again. I think it''s the satisfaction I get everytime I romp on it, hearing the exhaust, and knowing I did it myself .
Here''s a write up on Kooks install, but it pretty much applies to all of them.
Printable Version
Just put on some headers........ - 
Biggest PITA I''ve encountered in a long minute. 
