|
Manifolds to Thorley Tri-Y Headers
|
We had a "small" manifold leak from the drivers side of the 454.
And although I did a lot research on the Open Roads Forum, I thought I would simply remove the
manifolds clean the surfaces check the manifold for square if not get it re-ground put in gaskets
and re-bolt the manifold. Things didn't quite work out like that.
With much effort, working slow and about 1/2 a can of PB Blaster, I got the manifold off without
breaking any bolts. But there were 3 large cracks in the manifold, it was useless.
So started to consider Doug Thorley Tri-Y Headers.
So I then tried removing the passenger side manifold. As soon as I put a wrench on the back bolt
it broke and it broke deep completely below the head... I didn't even put any pressure on it, maybe
10 - 15 lbs of torque, Ok, so I went on trying to remove the rest
of them, I got out all but three of them. I tried everything, used the other 1/2 can of PB, tapping
with a punch and hammer, Breaker bar, tightening then loosening, and finally an impact wrench.
The impact wrench worked on two of them (after holding it on it for about 15 minutes switching from
reverse to forward) but the last one I had to heat with a torch and then hit it with the impact and
it finally came out.
Ok, so I pull the manifold out and what do you know it is cracked too.
Now its decided, Doug Thorley Tri-Y Headers.
I decide to finish the removal and try and remove the broken bolt. It doesn't look good it is
broken on an angle and below the surface of the head
My neighbor (78 yrs young) has seen my predicament and basically pushes me aside, He takes a center
punch makes a mark in as close to center as possible, then using a 1/8 inch drill bit, drills on an
angle to the head but square to the broken bolt, this gets the bit started, he then turned the drill
square to the head (even using a tri-square). After he drills all the way through the bolt he then
drilled it again with a 5/32 bit (the size required by the easyout).
He sprays a bit of PB into the hole, Taps the screw extractor into the hole and tries it, It wont budge.
He then heats the bolt with an Oxy-Acetylene torch and waits for it to cool for about 1 minute sprays more
PB into the hole and again taps in the extractor, he tries it. It moved!!! Slowly back and forth and
it is out!!!
Some pics of the cracked headers, all cracks where to the block side.
Drivers Side:
Passenger Side:
The headers are due to arrive Friday so I ran around all morning getting things like the new Magnaflow 12589
Muffler, clamps, anti seize, etc... I also run a tap through every manifold hole to make sure they are clear.
The headers finally arrive around 4:00pm. WOW they are real pretty!
So I spend 4 hrs + on the passenger side making a heat shield for the starter that will fit. I gave up
counting how many different versions I tried but at least 6. but I finally got one that shields the entire
starter, solenoid and knock sensor and doesn't touch the headers. But I did break the electrical connection
for the Aux Cooling fan sensor putting the headers in and out so many times. That was another $20.
It took me another hour to get the dip stick tube back in and to do it I had to cut it in two. I finally
got it in and reconnected it with a piece of stiff hose and clamps. Works fine.
Drivers Side:
Ok so the headers are on. The crossover pipe is on, the hanger for the muffler had to be welded in a different
place. The muffler goes on smooth and so does the rest of it... I did have to re-weld a couple of hanger brackets
on the tail pipe.
Crossover and Magnaflow Muffler:
Ok so I get in and start it. Its not that loud, Interior noise is the same, but outside it does sound nice,
deeper, throatier, more manly :).
DW gets in and puts in in gear nice deep idle, rumble but not annoying. she puts in neutral and gives
it a couple pokes on the gas, I can't help but grin it brings me back to my Mustang days, God do big blocks
sound nice.
I took it for a nice 70 or 80 mile drive, Wow Lots more power although I have the same problem as Sum1
after 2/3 throttle it loses power, so I am about to order the TBIChips chip.
Surprisingly it dramatically reduced cabin noise up front, probably because the manifolds were leaking so bad.
The temperature was also reduced and that meant even when climbing hills the clutch fan never kicked in.
If I have the drivers window open, you can hear it when you get on it up hills or taking off from a light
but putting along at 60-65 on flat ground it is hardly noticeable. Also when driving slowly by people and
getting there opinions, it is not annoying so in campgrounds it is no louder then a diesel.
I am very pleased with the outcome and recommend this upgrade to other.
|
|
|
