BBK Performance 16410 User Manual

INS-107

2005-2007 MUSTANG GT
LONG TUBE HEADERS
PART #’s 1641-16410

I N S T A L O N I N

S T R U C T I O N S

Included in this kit: Headers, O2 sensor extensions, gaskets, header bolts, collector studs, washers,
lock washers, and nuts.

Tools required: Jack, stands, 8mm, 13mm, & 22 mm open end wrenches, ratchet, swivel,
extensions, 13 mm, & 15mm deep sockets, small flat screwdriver 7/8” open end.

Step 1
Step 2

Step 3
Step 4
Step 5

DRIVER SIDE
Step 6
Step 7

Note;

Step 8

Step 9
Note;

Step 10
Step 11
PASSENGER SIDE
Step 12

I N S T A L

Disconnect 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.
Lift the vehicle as high as possible with jack and support with stands.

Unplug all 4 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.

Unbolt stock H-pipe from collectors and remove the H-pipe from the car.
Remove the bolts from the top and bottom of the steering shaft and remove the

shaft.

The maximum amount of working space is increased 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
easiest to access while working from under the hood)
Install BBK header and supplied gasket.

On some applications it may be easier to re-use some of the original stud type
hardware.

Insert and finger tighten the supplied collector studs.
Reinstall motor mount and dipstick tube.

Disconnect the electrical connections from the starter, then unbolt and remove the
starter from the bell housing.

Step 13
Step 14
Step 15
Step 16
Step 17
Step 18
Step 19
Step 20

Step 21
Step 22

Step 23
Note;

INS-107

Remove motor mount from the engine block.
Remove stock exhaust manifold and gasket.
Install BBK header and supplied gasket.
Insert and finger tighten the supplied collector studs.
Re-install motor mount and starter.
Lower motor mounts onto their mounting studs and tighten nuts.
Re-install the steering shaft.
Install matching short X-pipe (BBK 1636 or 1637) using supplied washers, lock washers

and nuts on the collector studs.
Install the oxygen sensors into the BBK headers and X-pipe.

Install the O2 sensor extensions by plugging them in between the factory wiring harness
connectors and the O2 sensors. If needed, trim the locating tabs off of the O2
sensor extensions with a razor knife or grinder as shown on page 3 .
Re-connect negative battery terminal.

After driving the car for a few hours it’s always a good idea to check and re­tighten the header bolts.