Installation of PowerFlow longtube headers..

[Toomnymods]

Well today me and ShiftyB (Drivingthemedian) embark on a mission to get rid of the stock exhaust manifolds on my truck today.. Pics of removal & install will be included with maybe a video or two of me at the track tommrow here in Fayettenam.. Tommrow is test/tune day in fayetteville so I'm definatly going to see if these will help me get lower than my previous best of 14.81 in the 1/4 I'm sure it'll help but how much, I'm guessing maybe 2/10ths to be conservative but we'll see

[rcantu]

good luck. i couln't do it myself.

[Toomnymods]

So far got the exhaust manifold heat sheilds, resonator tubes, and secondary o2 sensors out, cant break the torque loose on the exhaust manifolds though must be over 160ft lbs or torque, thier not rusted but they wont budge wont even squeak (sound it makes right before they give) any ideas??

[g356gear]

Originally Posted by Toomnymods

So far got the exhaust manifold heat sheilds, resonator tubes, and secondary o2 sensors out, cant break the torque loose on the exhaust manifolds though must be over 160ft lbs or torque, thier not rusted but they wont budge wont even squeak (sound it makes right before they give) any ideas??

I have talked to a couple people who have done headers and it is highly recommended to hit the studs with a penetrating lube every couple days for a week before attempting the install. The heat cycles and the penetrant will hepl break the studs loose. The last thing you want to do is break a stud because then the head has to come off.

[markislive78]

I had to use deep penetrating oil/lube.....warm you truck up again...then spary the lube...lube works best when the manifolds are hot/warm...i had the same problem.....warm her up spary on then garb a few beer will take around 30-45 to soak down in the threads

[Toomnymods]

ok thanks for the tips worked like a charm.. i doused it 2-3 times with the pb catalyst stuff, and now we are in the process of actually putting back in the Powerflow headers, man these are fookin huge compared to stock!! Get back to you guys later tonight trying to finish before it gets dark, already had a 2hr slowdown cause it was pouring down rain :/

[Titan1219]

does this require removal of the cats., and if so, do u not have emmissions testing where u live, so its not a concern for you?

I see you got the bolts off, but a ignersoll rand 1/2 drive impact gun and impact sockets work wonders.

[Toomnymods]

Finally got the Powerflow headers mounted up, and now I'm just putting back in the plastic black wheel liners and my tires.. Cranked her up and she idles MUCH DEEPER now the volume is much more pronounced and slight acceleration sounds stronger.. Haven't taken her WOT yet but I can imagine it'll sound awesome considering I'm probably moving 2x the air now without cats/resonators now will post pics/vids tommrow after getting back from the track..

[Toomnymods]

Took her out for a spin for a few WOT launches, and man this TRUCK SOUNDS LIKE A DRAG TRUCK NOW, LOL midrange power really plants you in the seat hardcore, and it's still in learning mode since I just installed these today so I imagine after nother 50-60 more miles it might even get stronger The Banks now has a true glasspack raw power sound which is very very loud probably atleast 2 to 3 times louder than banks with resonators.. I might put 1 resonator in right after the stock muffler though, I don't want it quite this loud but I want it louder than what it was on my truck with 2 resonators.. Anyone know a high flowing resonator that'll take the pop out of my exhaust when I start my engine?

[Titan1219]

screw the resonator. Find a quieter, but still free flowing muffler

[markislive78]

I feel ya pain..After i put my headers on my banks had to go...way to loud..The final straw was after i removed the resonators which happened last. Real raspy sounding..you could always try those 3'' dyno max bullet mufflers inline between the header and Banks flanges! Seem like it would take no time to mod the test pipes!

[Toomnymods]

What's your guys opinions on this? mod the testpipes and have 2 resonators and chance it sounding like it did before a tame banks? or put one dynomax bullet muffler after the banks muffler? I want more sound than what it was with the stock resonators, but not quite this much, it sounds as loud as a drag car/truck when I'm WOT. The power gains from these headers kick a$$ though it was definatly worth spending 950 bucks for the Powerflows and ceramic coating.

[Toomnymods]

Ok this is the start of the day. 10:00 A.M.


It is a must to have the wheels off and the fender liner removed, As you can see in this picture it is a cramped S.O.B.



The next thing you gotta do is take off the heat shields so you can get to the exhaust manifold bolts.
Dont be afraid when the bolts brake off the heat shield because you're just going to throw them away anyhow. The heat shields have a 10 mm bolt on them. you will have to use a fairly small 3/8 in drive ratchet.




this next picture shows the heatshield going around the o2 sensor.
The o2 sensor is in a terrible spot and you cant get enough leverage to get them off the manifold while its still on the truck.
Soooooo.....go ahead and cut that shield off with some tin snips.
After the manifold comes out, remember that you still have the sensors on there. Do not throw the manifold against the wall! just be patient and wait until the sensor is off.



Here it is. Only an hour into it and all is looking good!



In these next pictures, it shows the difference between the drivers side and the passenger side

Drivers side:

Passenger side:

[Toomnymods]

The rain is upon us so we went to get something to eat.


Rain drenched our working area.. but now we can return to work since the rain stopped for the most part..


Now the real fun begins of getting these damn header nuts broke loose.. tools required are 1/2" drive ratchet, 1/2" to 3/8 adapter, 3" and 6" 3/8 extensions, 14mmm socket deepwell and a normal size, and a 3/8 swivel. We didn't take any pics of the passenger side removal since those bolts are way way easier to get to. These bolts are torqued on pretty good and will require some muscle to break them loose.. Make sure you hose the bolts down real good with some PB catalyst before attempting to break them free.. Takes 2-3 applications and 1 hr of wait time to let it soak in good. Trust me you don't want to break your studs off your engine block


After you get all 8 bolts off you will need to loosen your drivers side engine mount, ( loosen the part that has the 4 nuts not the 1 nut) we didn't need to take the mount out all the way just loosen the nuts to where they are barely on there with 2-3 threads. Then place a jack under your truck and use a piece of a 2x4 on top to prevent crushing your oilpan. This is where we lifted the engine 2-3" to get the required clearance to remove the factory exhaust manifold..


Got to go to my girlfriends house finish the step by step process in a few hours..

[Titan1219]

$950 for headers! ill be passing on this one.