I bought a
set of Summit Shorty headers about a year ago and they have
been hanging on the wall of my garage since then. I decided
today is the day to install them. I figured I could do it in
an hour or two. I thought wrong.
I'll add them when done.
Stuff to have on hand:
didn't start until around 2:00 pm so that was a bad idea
right there. I'm going on a trip to Calico with a bunch of
other Bronco drivers next weekend so I have to finish it tomorrow.
by spraying every bolt I could see with a good amount of
Rust Free and let the whole thing have a good soak. The last
thing I want to do is break a bolt on the exhaust manifold.
After I let it sit a while I removed the 16mm bolts where
the Y pipe meets the manifolds. I had removed them before so
they weren't to hard to remove. I then pulled the
spark plug wires and taped the number order on them so I
wouldn't get them mixed up when reattaching them. I then
started backing off all the bolts. The drivers side came off
After I had
the bolts out I pulled out the manifold. I don't know how
this thing did not have an exhaust leak before since there
were no gaskets between the manifold and the heads.
the two end bolts then slipped the gasket in place. I then
started the rest of the bolts and turned them as far as
possible by hand. The bad thing is with the design of the
headers there is very little room between the bolt holes and
the pipes. This means you can't fit a socket over the
7/16" bolts. You have to use an open end wrench and
turn between 1/8 and 1/16 of a turn at a time. Still it only
took me about 15 minutes to change out the drivers side
Now the fun
began. I knew from other write-ups that the passenger side
is a real bear compared to the drivers side. The fuel
injection system hangs to the right side of the engine and
all the smog crap is in the way. You would think having a
lifted truck would make this easier from underneath, but not
really. The Y pipe meets there and they're is just no
room to reach up and do much to reach the back two bolts.
There is also the EGR valve attached to the manifold that is
one more thing in the way.
It took me
about an hour to wrestle out the old manifold and again
there was not gasket. At least I didn't have to scrape one
off. I spent another hour going up and down trying to get
the end bolts started so I could drop in the gasket. I ended
up having to start the front bolt and installing one in the
middle and snug it up so I could just reach in and get the
back one started from beneath. I then backed out the middle
bolt and dropped in the gasket. I got all the bolts snug
except for that damn back one then, with the back one only
1/2 way in but tight against the pipe I could not budge it.
I could get a wrench on it but couldn't get the room to turn
What I need
to do now is back off all the other bolts so I can move the
header forward enough to tighten the back bolt, then
retighten all the other bolts. I got dark really fast with
the cloud moving in so I decide to call it a night. Not 5
minutes after I moved the tolls in the house it started
raining. At least I didn't get wet.
1/28/06 I guess I
never updated this write-up. I will have to do it soon. But
in short I have to get my Bronco smogged soon and I was
getting a exhaust leak. I got lucky and it was just the
Y-pipe had worked itself loose. I managed to partially melt a
couple spark plug wires an before I put a new set I bought
on I need some exhaust wrap. Most auto parts stores won't
have this so you need to got to a place like Summit or in my
case I'm kind of lucky since PAW is only about 20 minutes
away. I don't like the look of the off white bandage wrap so
I also picked up a can of high temp flat black to go with
it. The directions say it helps to seal and protect them so
I guess it's a good thing.
This is one PITA job doing it on the
truck. It would be more of one to remove the headers first
so I started wrapping them up. The directions let you know
how long to cut each piece first. In the case of the front
one on the drivers side, it's 1 1/2" and just over a foot
long. With one bend it calls for 86" of wrap. That's over 7
feet. Sure enough it was just the right length. I took many
breaks since the bending over the fender to wrap these is
hard on the back and knees.
The passenger side was much more fun.
First thing I did was pull all the smog stuff so I could get
to it. I also had to do each pipe in multiple pieces since
the pipe were so tight I couldn't slip the wrap between
them. The back one was the most fun. Try not only wrapping
it one handed by touch only but then installing a zip tie
the same way. I also wrapped the EGR tube while I was at it.
I will have to let them dry and next
week I will paint them and button it up so I can get the