Any tips for changing out the header pipe?
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Road Warrior
Joined: Jul 2010
Posts: 1,816
Likes: 2
From: New Hampshire
Any tips for changing out the header pipe?
I'll admit it, lately have become a little gun shy on doing some wrenching on my ride. When I was a bit younger I used to be fearless in doing anything to my rides or vehicles. I guess after a few botchups lately on my last ride I've gotten a little apprehensive.
It looks pretty straight forward on changing out the head pipe but looking for any tips or things you may have learned in doing this....tools, tricks things that may things go easier if I do decide to tackle this.
Headpipe I'm switching to will probably be the Fullsac X pipe
Thanks
It looks pretty straight forward on changing out the head pipe but looking for any tips or things you may have learned in doing this....tools, tricks things that may things go easier if I do decide to tackle this.
Headpipe I'm switching to will probably be the Fullsac X pipe
Thanks
Club Member
Joined: Feb 2007
Posts: 1,678
Likes: 3
new gaskets, extra head nuts - pipe expander from harbor freight for the mufflers and a socket cut out to remove o2 sensors. Take your time, follow the instructions and you will not have issues. Don't over torque anything
Outstanding HDF Member
Joined: Oct 2009
Posts: 2,488
Likes: 30
From: Maryland near DC
lets see..
start from the back..mufflers first..
most bolts can be gotten off with 3/8" drive sockets
remove heat shields (if you need to) to make it easier to get to the
flange bolts at the heads..
put a piece or 2 of tape on the front down tube by the head pipe to stop scratches
head flange bolts come out with 1/4" drive deep sockets with extensions
except the one close to down tube, where you will need a reg. short socket and swivel..
you can probably reuse the flange gaskets, but check with the manufacturer of the head pipe to see if you need s.e. gaskets (some do, some don't)
if you need to replace the flange gaskets a hook will get them loose and then you can grab them with needle nose pliers
while you have the header off, remove the lower 2 bolts on the transmission and lock tite them back in to prevent future leaks..
use 2 peple 2 remove header as it is awkward to handle ( you might want to put a piece of carpet on the the floor just in case)
when installing leave everything loose until you have it all installed (even the mufflers) and then tighten it evenly..
it is hard to get to the front r. flange bolt with a torque wrench so I just tightened it to about the same as the rest and listened for leaks (I had none) and then tighten it some more if needed...
after driveing a few hot and cold cycles recheck all the bolts for tightness...
the 2 lower trans bolts are a bitch to get to and you may need to grind down a allen wrench to get them tight...
otherwise its pretty straight forward...good luck
start from the back..mufflers first..
most bolts can be gotten off with 3/8" drive sockets
remove heat shields (if you need to) to make it easier to get to the
flange bolts at the heads..
put a piece or 2 of tape on the front down tube by the head pipe to stop scratches
head flange bolts come out with 1/4" drive deep sockets with extensions
except the one close to down tube, where you will need a reg. short socket and swivel..
you can probably reuse the flange gaskets, but check with the manufacturer of the head pipe to see if you need s.e. gaskets (some do, some don't)
if you need to replace the flange gaskets a hook will get them loose and then you can grab them with needle nose pliers
while you have the header off, remove the lower 2 bolts on the transmission and lock tite them back in to prevent future leaks..
use 2 peple 2 remove header as it is awkward to handle ( you might want to put a piece of carpet on the the floor just in case)
when installing leave everything loose until you have it all installed (even the mufflers) and then tighten it evenly..
it is hard to get to the front r. flange bolt with a torque wrench so I just tightened it to about the same as the rest and listened for leaks (I had none) and then tighten it some more if needed...
after driveing a few hot and cold cycles recheck all the bolts for tightness...
the 2 lower trans bolts are a bitch to get to and you may need to grind down a allen wrench to get them tight...
otherwise its pretty straight forward...good luck
The biggest piece of advice I can give you from experience is to go to Harbor Freight and pick up a pipe expander. Like this one.
You will use this to expand the flange on the crossover pipe allowing it to slide easily over the new gasket. I went through two brand new gaskets before picking one of these up.
You will use this to expand the flange on the crossover pipe allowing it to slide easily over the new gasket. I went through two brand new gaskets before picking one of these up.
Road Warrior
Joined: Apr 2006
Posts: 1,469
Likes: 0
From: 310
My experience with that pipe expander from HF is that it's a POS!!! When I changed out my exhaust I was given the same advice. It broke and I took it back.
What I did was take whatever needed to be expanded to a muffler shop and let them do it with their hydraulics. I don't think he charged me for it, but I did take him a case of beer back.
What I did was take whatever needed to be expanded to a muffler shop and let them do it with their hydraulics. I don't think he charged me for it, but I did take him a case of beer back.
Road Warrior
Joined: Mar 2009
Posts: 1,326
Likes: 2
From: scurry, TX
I didnt have any issues with mine. It was one of the easiest mods I have done. Remember though - After a couple hundred miles go back and re-torque.
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My experience with that pipe expander from HF is that it's a POS!!! When I changed out my exhaust I was given the same advice. It broke and I took it back.
What I did was take whatever needed to be expanded to a muffler shop and let them do it with their hydraulics. I don't think he charged me for it, but I did take him a case of beer back.
What I did was take whatever needed to be expanded to a muffler shop and let them do it with their hydraulics. I don't think he charged me for it, but I did take him a case of beer back.
Just curious what broke on yours??? Mine was the o-ring. Figure I can prolly get a replacement at the local hardware store.
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