Torque Monster Headers

1
Torque Monster Headers

• How to install

On a 1996-2001 Ford Explorer w/ 5.0L V8
2
Why should you consider headers?

• The stock exhaust manifolds are poorly designed.
• They share a pipe between multiple exhaust ports
• They curve excessively to fit in the engine
  compartment
• They constrict gas flow since they have
  pinched-down pipes

3
Why should you consider headers?

• High Performance exhaust gives you better fuel
  mileage.
• Better gas flow allows cylinder chambers to
  evacuate exhaust gas quicker
• Less fuel is needed for engine to achieve optimal
  performance (computer will adjust automatically)
• Some constriction is still present for low-RPM
  torque.

4
Steps to Remove Old Manifolds

• Disconnect negative (-) battery cable and put
  vehicle up on jack stands.
• Remove front wheels.
• Remove front wheel-well covers (7-8 screws each).
• Drivers side Removal
• Disconnect drive shaft at its midpoint by a
  single bolt.
• Remove two bolts at exit port (connects to
  catalytic converters).
• Disconnect spark plug wires and remove spark
  plugs (cover holes with rag).
• Remove all 8 manifold bolts and remove manifold.
• A/C compressors heat shield may need to be
  removed.
• Should pull out through the wheel-well

5
Steps to Remove Old Manifolds

• Passengers side Removal
• Remove air cleaner box and tubing.
• Remove windshield-washer tank and radiator
  reservoir.
• Remove two bolts at exit port (connects to
  catalytic converters).
• Loosen nut on engine mount to the top of the
  engine mount stud.
• Use jack with a block of wood to raise up engine
  at its oil pan (3-4 inches).
• Disconnect spark plug wires and remove spark
  plugs (cover holes with rag).
• Remove all 8 manifold bolts and remove manifold.
• Should pull out through the top of the engine
  compartment.

6
Steps to Install New Headers

• Scrape cylinder head surface clean of old gasket
  material.
• Drivers side Installation
• Place single pipe for cylinder 5 and whole
  gasket up to head and finger-tighten its two
  bolts (/w blue thread-lock).
• Attach 5 pipe to main header and finger-tighten
  its two bolts.
• Finger-tighten remaining 6 header bolts (/w blue
  thread-lock) and check its alignment.
• Tighten all bolts to 35-40 ft-lbs.
• Install new exit port bolts and tighten to 40-45
  ft-lbs.
• Re-install all previously removed components on
  drivers side.