BBK Performance 16410 - Manual

INS-107
2005-2007 MUSTANG GT
LONG TUBE HEADERS
PART #’s 1641-16410
I N S T A L O N I N
S T R U C T I O N S
Included in this kit: Headers, O2 sensor extensions, gaskets, header bolts, collector studs, washers,
lock washers, and nuts.
Tools required: Jack, stands, 8mm, 13mm, & 22 mm open end wrenches, ratchet, swivel,
extensions, 13 mm, & 15mm deep sockets, small flat screwdriver 7/8” open end.
Step 1 Disconnect negative battery terminal
Step 2 Remove the bolt that secures the dipstick tube to the driver side cylinder head and
pull the dipstick tube straight up to remove it from the engine.
Step 3 Lift the vehicle as high as possible with jack and support with stands.
Step 4 Unplug all 4 oxygen sensors.
Step 5 Separate the cat-back system by loosening the 2 nuts on each band clamp and
prying the locking tabs up with a small screwdriver while sliding the clamp towards
the rear of the car.
DRIVER SIDE
Step 6 Unbolt stock H-pipe from collectors and remove the H-pipe from the car.
Step 7 Remove the bolts from the top and bottom of the steering shaft and remove the
shaft.
Note; The maximum amount of working space is increased by removing the motor
mounts from the engine by removing the nuts that secure the mounts to the
K-member and carefully jacking the motor up and supporting it with a block of
wood, then removing the fasteners that attach the mounts to the engine block.
DO NOT ATTEMPT TO LIFT THE ENGINE BY JACKING UNDER THE OIL PAN!
Step 8 Remove the stock exhaust manifold and gasket. (Some of the manifold bolts are
easiest to access while working from under the hood)
Step 9 Install BBK header and supplied gasket.
Note; On some applications it may be easier to re-use some of the original stud type
hardware.
Step 10 Insert and finger tighten the supplied collector studs.
Step 11 Reinstall motor mount and dipstick tube.
PASSENGER SIDE
Step 12 Disconnect the electrical connections from the starter, then unbolt and remove the
starter from the bell housing.
I N S T A L