I recently ordered some Flowtech shorty headers for direct bolt on my 5.9. The websites for them all say they bolt directly to stock setups, and are designed to. Well when trying to line them up my dad commented that they almost look like the headers are slightly bigger than the stock collector size on one of the sides. Going back and reading into some more reviews, some say that they had similar problems, but other say they went in fine. Not sure how there can be success with some and failure with others if its all the same size. The collectors im assuming are 2.5 just like the pacesetter/summit ones. Anyone know of this issue or has had experience with these headers? When we go to actually bolt we will obviously try and see if they fit fine as is even if it doesn't look it. Also, if it doesnt match, what would the cheapest and easiest proper fix be?

ALSO for those wondering about my post forever ago about a JB welded fix for that manifold bolt, well I had him take it out and retap as best as he could, and then weld in place a new bolt which is now in fine and holds the torque like a champ.

 

Stock collector size is 2" I believe. Since your stock manifolds are off you can measure them to verify. While you had the manifolds off, you could have welded a nut to the broken bolts and turned them out of the heads.

 

Bolt was broken of flush with the head and had to be drilled out over a few weeks. They were HELLA STUCK. Solution we ended with works well, it's essentially a permanent stud. Hmm well ill have to see. The flowtech only lists STOCK as it's sizing SO ill compare and if they aren't stock I'll definitely be contacting someone and giving some feedback, misinformation is the worst.

 

I've seen bolt on shorty headers for our trucks listed in both 2" and 2.5" collectors. When I had my stock manifolds off to remove broken bolts I measured the collector. My 99 had 2" id collectors.

I've always had really good luck welding a nut onto broken exhaust bolts and studs. When you weld it on, it gets the threaded part up enough to break the rust free. Turns right out every time. If your studs worked for you though that's great.

 

Thanks yeah! You could check truck pics over in the off topic. You can see my stud in one of the pictures on headers. If you like yellow, you should like the engine haha.