User Manual

INS135
1997-2003 FORD 4.6/5.4L
F-150/EXPEDITION/LIGHTNING
SHORTY HEADERS
Part#s 3515/0, 3516/0, 3518/0
NOTE!
WILL NOT FIT F-250 or SUPER DUTY!
Step 1
Disconnect battery
Step 2
Remove front fender liners/splash g uards. These are secured by push pin type
fasteners.
Step 3
NOTE!
Disconnect the EGR fitting from the driver side manifol d where applicable.
On 4x4 Models-
Set Parking Brake First! then unbolt the front drive shaft
from the front differential where it connects near the driver side exhaust
collector.
Step 4
Disconnect any oxygen sensors that attach the stock exhaust manifolds
Step 5
Remove the nuts that attach the mid pipe to the factory exhaust manifolds.
Step 6
Unbolt and remove the factory exhaust manifold s and gaskets.
Step 7
If necessary, transfer the EGR fitting and oxygen sen sors from factory manifolds to
the BBK headers.
Step 8
Install the supplied collector studs onto the BBK headers.
Step 9
Install the BBK headers using the supplied gaskets.
Step 10
Re-connect the mid pipes, and tighten the collector flanges using t he supplied
washers.
Step 11
Plug in all oxygen sensors.
Step 12
Re-connect and tighten EGR fitting if applicabl e
Step 13
Re-connect drive shaft on 4x4 Model.
Step 14
Re-install fender liners/splash guards.
Step 15
Re-connect battery.
Note; To prevent exhaust leaks after installa tion, BBK recommends that you go back and
retighten the header bolts after 100 m iles and that you add them to your regular
maintenance checklist.