How to install a BBK Chrome Tuned Length Shorty Headers on your 1996-2004 Mustang

CAUTION

Working under a car is hazardous. Use sturdy jack stands on a solid level surface. Always wear protective eye wear.

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

Step 1 Disconnect the (–) negative battery terminal, remove intake hose and air filter box, and remove strut tower brace (if applicable).

Step 2 Lift vehicle as high as possible with jack and support with stands.

Step 3 Unplug all oxygen sensors (removal from H-pipe is not necessary).

Step 4 Unbolt H-pipe from manifolds and catback system and remove.

Step 5 Remove motor mount to K member nuts.

Step 6 Carefully jack up engine (we recommend using a solid block of wood to place under the engine) until mounts rise out of K member. NOTE: Watch for any hang-ups such as wiring harnesses or hoses while lifting engine. Safely support in this position.

Driver-Side

7 Disconnect EGR by-pass tube from top of exhaust manifold.

8 Remove bolt from steering shaft at steering rack, move shaft aside.

9 Although not necessary you may find more working space by removing the motor mounts from the engine block.

10 Remove stock exhaust manifold and gasket. NOTE: On some vehicles it may be easier to access the upper exhaust manifold bolts from above the engine.

11 Install BBK header and supplied gasket. These headers have slotted mounting holes which will allow you to start some of the header bolts before placement.

NOTE: On some applications it may be easier to re-use some of the original stud type header bolts.

12 Insert one collector bolt down through each of the slotted holes in the collector flange.

13 Reinstall motor mount and reassemble steering shaft.

Passenger-Side

14 Unbolt and remove starter from bell housing.

15 Remove motor mount from block if needed.

16 Remove stock exhaust manifold and gasket.

17 Install BBK header and supplied gasket.

18 Insert supplied collector studs.

19 Reinstall motor mount and starter.

20 Lower engine into chassis and tighten nuts.

21 Reinstall H-pipe using supplied washers, lock washers and nuts at collector.

22 Lower car and reinstall intake hose and strut tower brace (if applicable).

23 Re-connect negative (–) battery terminal.