How to install a BBK Ceramic Long Tube Headers on your 2005-2010 Mustang

This Mustang Parts Installation Guide Works For

BBK Ceramic Long Tube Headers (05-10 GT)DOWNLOAD PDF

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.
Installation Time: (approx) a day

Installation

Included in this kit: Headers, O2 sensor extensions, gaskets, header bolts, collector studs, washers, lock washers, and nuts.

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.

Step 13 Remove motor mount from the engine block.

Step 14 Remove stock exhaust manifold and gasket.

Step 15 Install BBK header and supplied gasket.

Step 16 Insert and finger tighten the supplied collector studs.

Step 17 Re-install motor mount and starter.

Step 18 Lower motor mounts onto their mounting studs and tighten nuts.

Step 19 Re-install the steering shaft.

Step 20 Install matching short X-pipe (BBK 1636 or 1637) using supplied washers, lock washers and nuts on the collector studs.

Step 21 Install the oxygen sensors into the BBK headers and X-pipe.

Step 22 Install the O2 sensor extensions by plugging them in between the factory wiring harness connectors and the O2 sensors. If needed, trim the locating tabs off of the O2 sensor extensions with a razor knife or grinder as shown on page 3 .

Step 23 Re-connect negative battery terminal.

Note; After driving the car for a few hours it’s always a good idea to check and re-tighten the header bolts.

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