How to Install BBK 1-5/8 in. Chrome Long Tube Headers (05-10 GT) on your Ford Mustang

Follow these instructions carefully to ensure correct fitment and operation.

STEP 1: Disconnect the negative battery terminal.

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: Life the vehicle up as high as possible and unplug all the oxygen sensors.  

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.  

STEP 5: Unbolt the stock H-Pipe from the collectors and remove the H-Pipe from the car. 

Driver Side

Remove the bolts from the top and bottom of the steering shaft and remove the shaft. You may find more working space 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.  

Remove the stock exhaust manifold and gasket. (Some of the manifold bolts are easier to access while working under the hood)  

STEP 8: Install the BBK Header and supplied gasket. NOTE!!! On some applications it may be easier to re-use some of the original style stud type hardware.  

STEP 9: Insert and finger tighten the supplied collector studs, and re-install the motor mount and dipstick tube.  

Passenger Side

Unbolt and remove the starter from the bell housing.  

STEP 11: Remove the stock exhaust manifold and gasket.  (Remove the motor mount from block if needed) 

STEP 12: Install the BBK Header and supplied gasket. Insert and finger tighten the supplied collector studs, and re-install the motor mount and starter.  

STEP 13: Lower the motor mounts onto their mounting studs and tighten the nuts.  

STEP 14: Re-install the steering shaft.

STEP 15: Install matching short X-Pipe (BBK 1636 or 1637) using supplied hardware.  

STEP 16: Install the oxygen sensors into the BBK Headers and X-Pipe. NOTE!!! Be sure to add a small amount of anti-seize to the top thread of each oxygen sensor using the supplied anti-seize packet. As you thread the oxygen sensor back into the part the anti-seize will spread evenly throughout the threads. 

• Install the oxygen sensor extensions by plugging them in between the factory wiring harness connectors and the oxygen sensors. If needed, trim the locating tabs off of the oxygen sensor extensions with a razor knife or grinder as shown above.  

• Re-connect the negative battery terminal. NOTE!!! After driving the car for a few hours its always a good idea to check and re-tighten the header bolts.