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Yukon Denali, 2004 and Kooks LT Headers, Known Fitment Issues???

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Old 05-22-2015, 08:12 AM
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Default Yukon Denali, 2004 and Kooks LT Headers, Known Fitment Issues???

I ordered Kooks LT + catted connection pipes for March 15. Finally got them the other day after many delays and being sent the wrong product.

Get them and it doesn't fit at all.
The only thing I could think of is maybe if I cut the two pipes apart (they are welded as one unit) then maybe I could get it to fit. BUT the problem is that it looks like the flange is rotated and angled wrong so it might not help and I would hate to not be able to return this.

Well it looks like that family trip next weekend might not happen or I might have to get a rental.

Has anyone ever seen this issue before??? I couldn't believe my muffler is bent because the factory exhaust goes together perfectly.

Kooks part number 28523200
Kooks 28523200 01-06 1500 V8 3" Catted Connection Pipes
Attached Thumbnails Yukon Denali, 2004 and Kooks LT Headers, Known Fitment Issues???-20150522_085022.jpg   Yukon Denali, 2004 and Kooks LT Headers, Known Fitment Issues???-20150522_084903.jpg   Yukon Denali, 2004 and Kooks LT Headers, Known Fitment Issues???-20150522_084916.jpg  
Old 05-22-2015, 09:43 AM
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I have the same set up, however not installed yet. Mine are catless, but I don't have stock exhaust. I was going to temporarily hook mine to my current exhaust but ultimately I'm going to a 4 inch. I guess I'll see if mine fits. Have you contacted Kooks?
Old 05-22-2015, 05:33 PM
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What's up, man? I was actually going to take my truck to Knobels in PA next weekend but it doesn't look like it is happening. I only had 70 days to get this **** together, right?

I contacted the vendor I bought it through but not Kooks directly. I emailed Kooks before the purchase to verify the part number works so this sucks the big one. Took my muffler and con pipe to a shop today and the guy said he wasn't comfortable fixing it unless it was in the truck but he thought he could do it. Would just take time to cut the pipe up and reweld. Plus $$$$ that shouldn't need be spent.

You wouldn't happen to have measurements on your exhaust and the Kooks part you bought would you?
When are you planning on installing?
Old 05-22-2015, 06:06 PM
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What measurements do you need? I have the same mid pipes only catless.

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Old 05-23-2015, 06:36 AM
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I appears mine is off as well.
Old 05-23-2015, 07:05 AM
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I was looking at mine last night and thinking of using a BFH to close the gap between the two pipes. Bang on the fixed flange till it gets close and then cut the flange off. (Dirty secret: the fixed flange is actually steel and not SS, I used a magnet to verify.) Use a band clamp to try and seal the pipe. The slip fit part works ok. Then I can drive it to an exhaust shop and have them fix it.
Old 05-23-2015, 08:09 AM
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Update:

I was able to beat the pipes together with a BFH. But let me tell you it isn't a great fit. The flange is warped and I am upset it isn't SS. That means it will rust like crazy up here in PA, DE, NJ, MD, etc. Not even sure it will seal. But the bigest thing is that the holes still don't line up at all.
Attached Thumbnails Yukon Denali, 2004 and Kooks LT Headers, Known Fitment Issues???-win_20150523_090513.jpg   Yukon Denali, 2004 and Kooks LT Headers, Known Fitment Issues???-win_20150523_090354.jpg   Yukon Denali, 2004 and Kooks LT Headers, Known Fitment Issues???-win_20150523_090407.jpg  
Old 05-23-2015, 12:25 PM
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Sounds like there jig got messed up.
Old 05-23-2015, 04:47 PM
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I would advise against ordering this product. There is no telling how many of them are out there sitting on shelves that can't be installed (easily).

I am going to make a video showing the installed product.

Last edited by 2002_Z28_Six_Speed; 05-24-2015 at 05:54 PM.
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