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