BBK Performance 40100 User Manual

INS120

2005-2009 FORD MUSTANG

4.0L V-6 HEADERS

PART# 4010-40100

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

STEP 6
STEP 7

STEP 8
STEP 9
STEP 10
STEP 11
STEP 12
STEP 13

STEP 14
STEP 15

NOTE:

Disconnect negative battery terminal
Disconnect both cables from battery
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 oxygen sensors.
Separate the cat-back system by loosening the 2 nuts on the band
clamp and prying the locking tab up with a small screwdriver while
sliding the clamp towards the rear of the car.
Unplug the coil packs and fuel injectors
Unbolt stock Y-pipe from collectors and remove the Y-pipe from the
car.
Remove any o2 sensors that may be the exhaust manifolds
Remove the stock exhaust manifold and gasket.
Install the oxygen sensors into the BBK headers
Install BBK header and supplied gasket.
Insert and finger tighten the supplied collector studs
Re-install Y-pipe using supplied washers, lock washers and nuts at
collectors.
Re-connect the oxygen sensors
Re-connect negative battery terminal

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