When installing the header:

Put a bead of permatex Copper Core RTV around the dome (USE MORE THAN I DID). if you do not do this now, then you will not be able to do it when you get them on there because of space constraints.



Slip the header over the two studs that were left from the OEM manifold. Then put the nuts on (just start BOTH of them, otherwise, you will have to back them out because the bolt goes flush with the tube and you will not be able to get the second nut on).

Tighten these inside bolts down until they are barely snug...LIGHTLY snug with a bit of wiggle room, then go to the outside bolts. ALWAYS GO INSIDE TO THE OUTSIDE FOR THESE BOLTS TO ENSURE THE PART SEALS CORRECTLY. TIGHTEN HEADER BOLTS BEFORE YOU CONNECT THE FLANGES


Finished drivers side:



Finished passenger side:

 

After the header bolts are tightened to 21 ft lbs (yeah right, you can use a torque wrench for a total of 3 bolts between both headers), take it for a spin and drive a few miles to get them hot. They will not be shiny anymore and you will smell something funny (especially with all that PB blaster and oil burning...smells like plastic burning).

Then you let the headers cool and retorque them. Retorque them every month.

CLOSING TIPs:

1. If you are a beginner, set aside 12-18 hours for this (day and a half) because you will need it...especially if you have a cali truck with thise big fat cats.

2. Do the drivers side FIRST, then the passenger side. The drivers side is the most cramped, and after cursing because these header bolts make you tighten them down 1/4 of a turn per time with a CRESCENT wrench...you will be happy to know the other side only takes about 2 hours.

*** I took off the heat shields, but I will be putting them back on next weekend. These headers look HOT.

 

Oh, and the gold thing with the green sitcker is a Fitch Fuel Catalyst. Not sure if it helps MPGs a whole lot, but I can run 91 octane with the 93 tune, and I have never gotten bad gas since installing it. I would not recommend it for the $250 price tag.

 

Dude, you've gone postal!

 

Well, it is my first DIY attempt in the 6 years I have been a member. So, I was due for one.

I might even redo the TPS cleaning one that was lost when the site changed over.

 

Nice DIY, looks like fun. And you knew this question was coming...Do you notice any performance difference with them?

 

I actually answered that in the first post. But yes, I was not expecting a gain I could feel because I put Edelbrock's on my 1996 and noticed no difference. However, I think the power gain was more pronounced because I also have 1.7 roller rockers and a tune. My 1996 did not have roller rockers and only had the MOPAR PERFORMANCE PCM.

I was not expecting a gain, and I got a good one. I pushed it to 1/2 throttle and it threw me back in my seat...rather hard. I think they really opened up the other mods I did. Oh, and I am running the stock airbox.

 

is that a chrome power steering pump?

yeah the collector bolts suck, but it only took me 2-3 hours to put on my pacesetter shorties, but i did spray all the bolts every other day with pb blaster for like a week before i attempted this.

with the headers i thought i would get a different exhaust note and maybe 2-3 horse power, but after driving it i noticed almost no sound difference but more performance than i expected

and for the header bolts, i went with stage 8 locking bolts. they were $60 from ebay, 3-piece design never comes lose and they're nickel plated and look real good on my headers.... ive had them for a couple of months and still at 21 ft lbs

 

1. No, it is a brand new power steering pump.

2. The sound actually gets lower with headers...the thing is that people ussually delete cats when doing headers...hence louder. I was very surprised with the power. I got the headers more for looks, and got a good brand because I did not want them to rust out. Even coated headers have spots of rust that form.

3. About the stage 8s...I would rather not have to take bolts out and put them back in right now. I will just retorque every month or so. I have only put 9K miles on my truck since Jan 2008, and that included moving from California to Arkansas. So I hardly drive my truck. If the weather is good, I ride my Harley.

-Dan

 

i also used the stage8's. amazons the cheapest and no shipping. hung the manifold gasket they sent me with the headers up on the wall and put on a remflex gasket on. also got it off amazon. amazon has some great prices on stuff and usually free shipping if you are in no hurry. i put antiseize on my header bolts too. we will see if that helps here in the next month when i get ready to take them back off.

something that i did seemed to help alot was take my wheels off and wheel liners. it allowed me to get to everything pretty easily.

great write up too.