Right up front this is not something I would ever again attempt in my garage. My hands are just now recovering enough where I'm able to type this long diatribe.
So here goes... I ordered the SLP stainless ceramic LTs, X, and HF cats a few weeks back. Quality hardware right out of the box and the instructions seemed simple enough so I figured I'd give it a shot.
Raised the car on jackstands, loosened the rack, uncoupled the steering column by removing the intermediate shaft pinch bolt and removed the dipstick tube. All stated well. Was able to remove the upper nuts and studs from the stock manifolds without too much trouble. Was able to remove the front, and back two nuts on the bottom-both sides. I then unhooked the O2 sensors and disconnected the stock manifolds at the midpipe and removed stock H. Then the fun began! I couldn't get to those last two bolts on the stock manifolds. They were smack between the engine mount and the bottom of the stock manifold (clearly assembled before it was dropped into the cradle). I tried every tool I owned and nothing worked. So now I had everything in pieces and couldn't finish the job. I was pissed.
So I gave up for the night and the next morning I buttoned everything back up (kind of half-a$$ed and loud as hell) and stopped by the muffler shop to have them remove those two tricky bolts. Got back home and took everything apart again. This time was able to remove the stock manifolds. Of course by this time my hands look like they've been through a meat grinder. From here on, it was almost a piece of cake. Installed the new headers from underneath the vehicle with no problems. Installed the new X & cats and bolted everything back up (except those two tricky bolts by the mounts which I took back to the shop to have them do.
Moral of the story... Never fully trust directions that come with aftermarket parts!. Especially if they seem almost too simple. Those of you without a lift and impact wrench, take my advice and hire someone to install your headers. Your hands will thank you!
In the end, the headers are on and sounding great. Gained about 20 rwhp/28 rwtq. Best mod so far. Will post some pics when I get a chance.
why didn'tyou just remove the motor mounts? 1 day and you'da been done. BTW, the rack didn't need to be loosened.
But they R nice headers. I have the same thing w/o cats
Yeah I guess I could have jacked up the engine and pulled the mounts. As for the rack, I couldn't disconnect the column without rotating the rack forward. How were you able to do it without?
I learned this from my C4 corvette, from every car after that, i pledged to have any kind of work that needs to be on a lift, have it done by a shop with a lift! I had no knuckles left too when i installed my headers. On my C5, i paid someone 60 bucks a hour to install them, and it took 2 hours. was well worth it.
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2006 Deluxe GT 5 Spd Manual Tungsen Grey with black painted stripes, 20 x 10 konig beyonds, kw V3 coil over kit, BMR Chomoly Panhard rod, BMR Boxed Subrames, BMR Upper Strut, BMR lower control arms, BMR Upper Control Arm, Eibach Sway bars, Prothane Eurethane bushing kit. Bassani cat back.w/ x-pipe + hi flow cats, Roush Rear Spoiler, Street Scene Body kit,Street scene grille, 3D carbon louvers, HID system, Raptor Shiftlight with Speed of sound pillar guage, C&L with Preditor 91 Custom Tune
I learned this from my C4 corvette, from every car after that, i pledged to have any kind of work that needs to be on a lift, have it done by a shop with a lift! I had no knuckles left too when i installed my headers. On my C5, i paid someone 60 bucks a hour to install them, and it took 2 hours. was well worth it.
Yeah I guess I could have jacked up the engine and pulled the mounts. As for the rack, I couldn't disconnect the column without rotating the rack forward. How were you able to do it without?
Unbolted the shaft from the rack and slid the shaft up enough to clear the rack and swiveled it out of the way.
The shafts are designed to collapse in a front end impact so the shaft slides into itself. They've done this since along time ago.
Having been in the bussiness as long as I have, I just don't feel comfortable having someone else work on my toy. But they can work on the wifes vehicle.
Unbolted the shaft from the rack and slid the shaft up enough to clear the rack and swiveled it out of the way.
The shafts are designed to collapse in a front end impact so the shaft slides into itself. They've done this since along time ago.
Having been in the bussiness as long as I have, I just don't feel comfortable having someone else work on my toy. But they can work on the wifes vehicle.
I didn't realize the shaft would move enough without loosening the rack. Makes sense so you don't end up getting impaled by the column in an accident. Oh, well, too late now.
My Long Tube Header Install Nightmare 
