s7ven

Best write-up I've seen on here, excellent job! I'll be doing Kooks Headers + Kooks True Duals with motor mounts so I will definitely be printing this out and following it step-by-step.

The only thing I'm really worried about is snapping a bolt. I still remember the nightmare of breaking off 2 bolts on my Ford Escort's thermostat housing...took lots of PB Blaster, torch, and a good pair of vice grips to get them out....

If I spray the **** out of everything with PB blaster a few times 24 hours before I do this, will it make getting bolts out easier?

Huntr1117

iTrader: (18)

When I installed LTs on my brothers car I sprayed everything with PB the night before and again right before I started working on it. All the bolts on the y-pipe pretty much broke off. I was lucky because I had no idea how I was going to get to and be able to cut the bolts off the y-pipe that connected it to the manifolds. All the other bolts came off pretty easy. Glad I didn't break any off in the heads.

s7ven

Yea, I don't really care if the bolts break off in the exhaust since I'm taking it off anyway but I'm just worried about manifold bolts.

cyberkill

Thanks! Hope it helps!

Yeah the cat bolts and Y bolts broke, but then again, like you said, they don't matter because you're replacing them anyway.

I didn't have to PB Blaster the manifold bolts at all, they came out without any extra effort, but yeah, I'd assume PB Blaster overnight (and during) would help.

Blk2kSS

iTrader: (6)

nice write up

samball7

I have had the same setup except the motor mounts and when it hit the gas aggressively i get a bad vibration only started with the headers and y-pipe dou you think its the y-pipe hit underside under torque and what should i do

demonspeed

iTrader: (7)

Add me to the list of those who found your write-up invaluable. I just wrapped up this same install at 2:15 this morning

Motor mounts were definitely the most time consuming thing I've done to a vehicle -- what a PITA! Nonetheless, the "BG" jack method saved some major time.

Another point to note is that the TSP Y-pipe now comes with stainless band clamps rather than the guillotine style. The negative about that is it no longer includes the larger "step" style clamp for the collectors. I also had to reuse the factory I-pipe clamp because the 3" were too big (ie: they didn't include a 2.75" clamp).

02 NHRA

Did your clamps tighten up ok? The band clamps TSP sent with my ory didn't tighten anything. I took a impact to all of them and you would still be able to pull the inner pipe out...was really kinda pissed about that. I had to send the wife out to get a bunch of C-clamps to replace the crap ones that didn't work.

demonspeed

iTrader: (7)

I think if they'd notch all of the connections like the I-pipe comes from the factory then they'd seal a lot better. I had to wrench on them to get them to tighten, but I think they're good. I was going to jack it up this week though to re-tighten. I did, however, need to buy a TorcTite clamp for the passenger side connection as the OD pipe just seemed way too big and wouldn't not tighten whatsoever.

WhiteHawk489

just used this write-up for my BBK LT and MM install this week and got it done in about 20 hrs 100% by myself!!!! this write-up was priceless!!! thanks cyberkill!

99'CajunFirehawk157

iTrader: (57)

Congrats, but I hear the BBK headers fit really good and if memory serves, BBK=1 3/4 and some others like TSP are 1 7/8 so I am sure that extra clearance helps too.

LetsRide

iTrader: (3)

Saving thread for close future reference! I'm glad I ran across this thread without a doubt. TSP LT and ORY install will make this much easier I'm sure. Might as well go for the motor mounts as well.

WhiteHawk489

Yeah they are 1 3/4". Fit great! Tuck up better then the stock headers/cats/y, I was really impressed! Passenger side is a hair too tight against the floor pan heat shield but that was the only issue.

Thomas Aquinas

iTrader: (6)

Excellent write up!!
This helped a bunch when I was doing the motor mounts. The trick with the scissor jack worked perfect. I can't believe trying to install the bolt without using the jack method.

I installed kooks 1 7/8 w/o air. Passenger side was super easy. For the driver's side I only removed the oil filter. Looking back on it, I probably could have unbolted the steering shaft because it was just a little snug. Otherwise, real easy.

Thanks again for the write up.

demonspeed

iTrader: (7)

Steering shaft removal > oil filter removal. I had a ton of room with the shaft out and the filter still on. Ease over [oily] mess any day

Thomas Aquinas

iTrader: (6)

The instructions that came from Kooks, called for the oil filter to be removed, but not the steering shaft.

There is definitely a sweet spot on the driver's side which the headers will pop into place.

cyberkill - Again, why isn't this a sticky?

Probably took me around 20 hours as well, over a 3 day span, working at a moderate pace.

cyberkill

Lol, iono? Maybe they're waiting for me to actually add step numbers and bolt sizes before doing so. Haha.

In any case, I'm not sure I like this imageshack thing, as they're really unreliable. I'd say 80% of the pictures show, but there's that 20% that don't show unless you refresh a million times...

I'm thinking of moving them to my Comcast web space, and see if that makes a difference. When I am actually un-lazy enough to do that, I'll add the step numbers while I'm at it.

cammed05pbm

Thanks for the great write up. I used this last week to throw on some ebay headers and this was a big help. Had a bunch of issues: O2 sensor on driver's side hitting heat shield, both sides hitting k member, primary hitting the steering shaft, y pipe not mating to i pipe, but it was nothing a sawzall, a grinder and a BFH couldn't fix.

s7ven

Bump! This still needs to be a sticky!!!

Everything went great on my install all thanks to this write-up. I was able to get headers, spark plugs/wires, motor mounts, and Kooks true duals installed all within about 30 hours. I followed your write-up step for step and never ran into any issues other a few stubborn bolts but a little heat and PB Blaster took care of those. That scissor jack idea is a life-saver. Thanks again for such an awesome write-up.

demonspeed

iTrader: (7)

As a newly-appointed mod, I now bestow stickiness unto this thread of ye infinite wisdom!