GP218S STAINLESS HEADER NO EGR, AUTOMATIC ONLY FORD F-150 TRUCK 5.4L 2/4WD NEW BODY STYLE FORD EXPEDITION 5.4L 2/4WD LINCOLN MARK LT TRUCK 5.4L 2WD Thank you very much for purchasing our Gibson header for your vehicle. If you need further assistance, please do not hesitate to call our Technical Department at (800) 528-3044 Monday through Friday 8:00 a.m. to 5:00 p.m. PST.
WHEN THESE INSTRUCTIONS ARE FOLLOWED PRECISELY, YOU WILL FIND THE INSTALLATION OF YOUR EXHAUST SYSTEM TO BE RELITIVELY SIMPLE. WE CANNOT OVER EMPHASIZE THE IMPORTANCE OF ADHERING STRICTLY TO THIS PROVEN APPROACH, AS IT WILL VIRTUALLY ELIMINATE ANY DIFFICULTIES, WHICH YOU MIGHT OTHERWISE ENCOUNTER.
SUGGESTED TOOLS 7/16” WRENCHES (VARIOUS LENGTHS) 7/16” SOCKETS (SHALLOW AND DEEP) ½” WRENCHES (VARIOUS LENGTHS) 9/16” SOCKETS (SHALLOW AND DEEP) 5/8” SPARK PLUG SOCKET 7/8” OPEN END WRENCH 15MM DEEP SOCKET 15MM BOX END WRENCH 31MM OPEN END WRENCH (A LINE WRENCH) 3”, 6”, AND 12” EXTENSIONS FOR SOCKETS SCREWDRIVERS AND/OR NUT DRIVERS (FOR HOSE CLAMPS) SAWZALL (HAND –HELD POWER HACK SAW) LUG NUT WRENCH HIGH TEMP SILICONE (ULTRA COPPER BY PERMATEX) GOOD RUST PENETRANT
IT IS CRITICAL THAT ALL BOLTS BE RE-TIGHTENED HOT AFTER ABOUT 20 MINUTES OF OPERATION TO PREVENT GASKET FAILURE. NOTE: HEADERS ARE NOT MEANT TO SERVE AS “EXHAUST SYSTEM SUPPORT HANGERS”. ADDITIONAL HANGERS MAY NEED TO BE ADDED AT THE TIME OF THE INSTALLATION OF THE HEADERS SO THAT THE EXHAUST SYSTEM SUPPORTS ITSELF WHEN THE COLLECTOR BOKTS ARE REMOVED. HEADERS THAT HAVE “SAGGED” DUE TO THE LACK OF SUFFICIENT EXHAUST SYSTEM SUPPORT WILL NOT BE REPLACED UNDER WARRANTY.
INSTALLATION INSTRUCTIONS NOTE: INSTALLATION OF THESE HEADERS REQUIRES AN ADEQUATE WORK SPACE, GENERAL MECHANIC'S TOOLS, GENERAL MECHANIC "KNOW-HOW" AND A REASONABLE DEGREE OF EXPERIENCE. 1. PLACE VEHICLE IN A LOCATION WHERE THE FLOOR IS SOLID AND FLAT, WITH ADEQUATE LIGHTING. DO NOT ATTEMPT TO WORK ON A HOT ENGINE. HEAT CAUSES METAL TO EXPAND AND MAKES REMOVAL OF FASTENERS DIFFICULT. DISCONNECT THE BATTERY CABLES FROM THE BATTERY.
5. DISCONNECT ALL O2 SENSORS. THEN FROM UNDERNEATH THE VEHICLE, LOOSEN THE BOLTS CONNECTING THE Y-PIPE ASSEMBLY TO THE EXHAUST MANIFOLD. (ON 4X4 MODELS, DISCONNECT THE FRONT DRIVESHAFT BY REMOVING THE 4 BOLTS ON THE FLANGE, AND LET THE DRIVESHAFT HANG OUT OF THE WAY.) 6. TO HELP AID IN THE REMOVAL OF THE FACTORY MANIFOLDS IT IS SUGGESTED THE STARTER BE REMOVED TO MAKE FOR AN EASIER INSTALLTION.
9. ON THE PASSENGER SIDE, AGAIN WORKING THROUGH THE WHEELWELL, REMOVE THE NUTS ATTACHING THE MANIFOLD TO THE HEAD. REMOVE THE MANIFOLDS ATTACHING STUDS. (NOTE: MUST REMOVE ALL UPPER AND LOWER STUD BEFORE MANIFOLD WILL COME OUT.) 10. USING A SCRAPER REMOVE ALL CARBON DEPOSITS AND HIGH SPOTS FROM HEAD SURFACE, USE CARE NOT TO GOUGE THE ALUMINUM HEADS. 11. NOTICE ON THE DRIVERS SIDE HEADER THE UPPER BOLT HOLES ARE SLOTTED. INSTALL THE GASKET WITH THE HEADER BOLTS LEAVING AT LEAST 3/8 OF INCH GAP.
13. BEFORE INSTALLING THE PASSENGER SIDE HEADER LOOSEN PASSENGER SIDE MOTOR MOUNT BOLTS AND RAISE ENGINE. BE SURE TO FIND A SECURE POINT TO RAISE ENGINE. ONCE ENGINE HAS BEEN RAISED SLIDE PASSENGER SIDE HEADER INTO PLACE FROM UNDERNEATH THE VEHICLE NOT USING ANY BOLTS. (NOTE: HAVING INSTALLED HEADER BOLTS AND GASKET BEFORE SLIDING HEADER INTO PLACE WILL INTERFEAR WITH THE CORRECT AMOUNT OF CLEARNCE TO SLIDE HEADER IN.). 14.
20. RE-CHECK EVERYTHING! 21. START THE ENGINE, CHECK FOR LEAKS AND TEST DRIVE. THEN LET THE ENGINE COOL AND THEN RE-TORQUE THE HEADER BOLTS. IT WILL BE NECESARRY TO RE-TORQUE THE HEADERS AFTER THE NEXT 100 MILES OR LESS. 22. PERIODICALLY CHECK AND RETIGHTEN THE HEADER BOLTS. NOTE: IT IS NOT UNUSUAL WHEN INSTALLING HEADERS TO GET BURNING SMELL.
