SW header install prep time...

[a_d_a_m]

March 24th, weather permitting, will be the day. A buddy with a lift is going to open up his shop for me to get this deal done. Hoping that the ten winters off the roadway have kept the car reasonably non-crusty and I don't snap anything...but it was a Chicago car from '03 to early '08...

Gaskets. Been doing a ton of reading and I'm seeing that people are reusing their OEM factory exhaust gaskets? Or am I mistaken in this? Seems really odd to me. I was considering going OE style but new. What say you?

Studs. I think I'm gonna use the SW-supplied bolts. Haven't heard any issues lately. Anti-seize on them, yes?

Dipstick. Heard the header revision circa 2010-11 fixed this and I should be able to reuse my OE dipstick?

Tune. Marty will be getting my tuner via USPS tomorrow and setting me up with a tune so I should be all set. Not sure what the turnaround time will be and I'm not trying to rush him. SO: if it doesn't get back to me in time, can I limp the car home with the stock tune (20 freeway miles)? As long as I don't WOT it, I think I should be alright, just looking for confirmation.



I never post pictures of mods, but maybe I'll try and take some pics along the way so as to assist those in the future.

[justbob]

At this point order new factory gaskets, they are cheap thru Tasca.

I prefer using the 10 packs (x2) of 8mm studs/nuts sold in the exhaust isle at Advance. Or splurge for S.S. Their lock nut included has never walked and hanging them just seems easier. You will have to cut a couple down on the passenger side however.

Dipstick is fine but be careful not to snap it off in the block. Been there once and that sucked..

Tune is fine, it will just eventually set a code because the o2’s are farther back.


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[musclemerc]

I used SS studs. way stronger than bolts
I used stock dipstick but you have to install it with the DS header
The stock gaskets are best because they're layered SS. Should be OK to reuse yours unless you had a previous issue.

Spray cold hardware with a good penetration oil. Should be easy!

[Comin' in Hot]

I have a thread about the studs.... I’ve done two sets and I’ve never had an issue.

https://www.mercurymarauder.net/foru...ad.php?t=95070

And get new OEM gaskets.

[a_d_a_m]

At this point order new factory gaskets, they are cheap thru Tasca.

The stock gaskets are best because they're layered SS. Should be OK to reuse yours unless you had a previous issue.

Two different opinions... I may just make sure the local dealer has some ready to go at the parts counter and see how they look upon removal. I am pretty sure I replaced the DS gasket when I had that cylinder head off...not 100% sure though.

I prefer using the 10 packs (x2) of 8mm studs/nuts sold in the exhaust isle at Advance.

Dipstick is fine but be careful not to snap it off in the block. Been there once and that sucked..

Tune is fine, it will just eventually set a code because the o2’s are farther back.

10-4 on all of this. I was thinking about those style studs but prefer something SS. As Travis said I would want to go stainless on those.

I used stock dipstick but you have to install it with the DS header

Right on. I shortened my stock dipstick 1/4" or so when reinstalling last time, so should go in easy as it was only 30k miles ago.

Thanks for your input thus far, gents.

[a_d_a_m]

I have a thread about the studs.... I’ve done two sets and I’ve never had an issue.

https://www.mercurymarauder.net/foru...ad.php?t=95070

Saw those on Amazon...really like 'em. I think crownvic97 also recommended them in another thread, but I wasn't able to find them. They are ordered and should be here within the week. Thanks CIH.

[Zack]

Buy new gaskets
Have a cutoff wheel ready.
Slice the flange between 6&7
It will clear the dipstick no problem
You will need to heat the EGR nut until it is glowing orange.

[a_d_a_m]

Gotcha on that stuff...thanks dude. Will miss your tune.

You will need to heat the EGR nut until it is glowing orange.

I assume you mean the EGR nut on the exhaust side? I had that thing loose in 2012 when the motor was apart - maybe I'll get lucky? Did it back then with a breaker bar and a lot of prayer...

[offroadkarter]

I've used bolts and studs, agree studs are the way to go.

New gaskets for sure, you can't reuse an exhaust manifold gasket. You'd get a leak for sure.

I've cruised my car around on the stock tune before, you'll be fine with the one you have on there while waiting. Back when my 04 was NA I asked lidio to send me a revision for the headers and he told me all he normally does is bump the enrichment by 5%, doesn't require any radical changes from the normal tunes.


edit: oh yeah, start soaking the factory studs in something like PB Blaster, Liquid Wrench or Kroil now, and keep doing it until the day of install. When Blackened300a and I did the header install on my 04, I think we might have snapped off 1 stud which easily came out with vice grips.

When I did the engine swap on the 03, I used a propane torch and heated all the studs up, none snapped. I had also soaked those in advance by a couple of days.

[a_d_a_m]

PB is a Cleveland company so it's widely available - haven't seen Kroil anywhere local so will probably go with that. Thanks for the input. All of these posts are giving me the courage to do this!

[blazen71]

I reuse the factory gaskets without issue, but new oem gaskets are cheap insurance. Use the SS stud and nut kits. If you don’t want to cut your DS header flange, get a lokar flexible dipstick.

[Joe Walsh]

I reuse the factory gaskets without issue, but new oem gaskets are cheap insurance. Use the SS stud and nut kits. If you don’t want to cut your DS header flange, get a lokar flexible dipstick.

+1

I reused the (very good quality) OEM mulit-layer S.S. gaskets.
No problems nor leaks at all.
Header nuts were still tight when I pulled the dead 5.0 DOHC 12 years later.

Do NOT use cheapie paper or cork type gaskets that come with many headers.

Pull both front wheels for access through the wheel wells and have plenty of;
- Ratchet extensions and U-joints
- Patience
- Liquid Bandage

[a_d_a_m]

Liquid Bandage

The only Liquid Bandage I ever use is beer. I don't suppose that's what you're referring to...?

[Joe Walsh]

The only Liquid Bandage I ever use is beer. I don't suppose that's what you're referring to...?

LOL....

Liquid Bandage is the goop that you put on your cut, bleeding hands to keep the blood off of your new coated headers.
Liquid Courage is Beer
Liquid Pain Killer is Bourbon

[a_d_a_m]

I hope to not need it!