I put the headers on last night.

It went well with a little swearing as I fit the Y-pipe together under the truck.

It was difficult to get the pieces slid together all the way.—be sure the tubing slides together easily before you get under the truck. My pieces fit well, but fairly tight. This is good and bad.



It took me about 4 hours including dinner.



The bolts for the y-pipe to stock manifolds are TIGHT. And you will need a universal joint to get your socket on them (15mm deep 6 point). The cats will not allow a straight extension on most of the nuts.



I removed my tranny crossmember to make things easier. (21mm socket and wrench for the frame bolts, 15mm deep socket for the tranny to crossmember nuts)



I stuck a 2x4 between the torsion bar frame member and the tranny after I jacked it up so the jack or stand wouldn’t be in my way.



To make things easier, I used a ratchet strap and pulled the cat back towards the rear. Removing it would have made Y-pipe assembly easier.



After the stock Y was out, I removed the plug wires and then manifolds. It is not necessary to remove the spark plugs. The rear bolt on the driver side is hard to get a tool on. I used my 13mm gearwrench. Those things are a lifesaver. Without it you may need to use a regular wrench and pull 1/16 turn, remove, replace, pull 1/16 turn, repeat for 30 minutes! I pulled the driver side manifold out the bottom, passenger side out the top.



The headers went in pretty easily. I had to jack up the passenger side a few inches (tire still touching the ground) to get that side in from the bottom. The tranny lines and aluminum heat shielding on the firewall made it a bit tight. I taped my headers up to keep them from getting scratched while I got them into place. The driver side was easier, just a little gentle maneuvering into place from the bottom also.
more info to come

Here is a clip of the idle & rev before.

http://s87.photobucket.com/albums/k1...headers020.flv

 

Idle and rev after headers.

 

A few pics of the install.
2x4 under tranny





Gearwrench on drivers side bolt.


Y-pipe comparison.


Header comparison.

 

Easy take off before headers.

http://s87.photobucket.com/albums/k1...headers016.flv

Easy take off after headers

 

Rolling on throttle, WOT through 1st, most of second, before.

http://s87.photobucket.com/albums/k1...headers017.flv

Rolling on throttle, WOT through 1st, and second, after.

http://s87.photobucket.com/albums/k1...eaders2012.flv

 

Wow, thanks for all the stuff! Pics, vids, directions. I thought someone said they didn't have a Off Road Y to fit our trucks yet? Or is yours not a 6.0? It sounds good! How does the power feel? Is it louder inside?

Nevermind about the 6.0 question, I realized it says 5.3 in your sig.

 

that cam has a big bark for being so small! are you tuned for it?

 

Thanks guys, it is tuned (was before the headers) It runs well.


These tranny cooler lines were touching, I had to convince them to make more room.



Plenty of clearance at the steering shaft.


1/2" from the frame.

 

how did you sanke them in with the 4wd, from top or bottom? any 4wd areas in the way

 

Dude you're killing me. My Thorley's came in today and they're sitting in the box. Not sure when I'll get them installed, but your vids aren't helping my patience!