Stainless Works 1-7/8 in. Headers w/ Catted X-Pipe - Performance Connect (15-16 5.0L SuperCab)

DESIGNED FOR 145” WHEELBASE

Thanks for purchasing Stainless Works Muscle Flow Headers for your Ford F-150 5.0L. We have gone to great lengths to make sure that our exhaust systems fit and sound great. Please follow these steps to ensure that your installation goes as planned.

Step 1. Stainless Works recommends the use of Hi-Temp RTV silicon gasket maker as an option to or in conjunction with the use of factory gaskets. The recommended RTV is Valco Sensor-Safe aluminum All-in-one or Permatex P/N 101BR, available at NAPA and other retailers.

Step 2. Disconnect the battery before starting work on the exhaust system for your vehicle.

Step 3. Your exhaust system can be installed by a weekend warrior but the use of a lift is recommended for ease of installation. If using a jack, the vehicle must be placed on a level hard surface and jack stands are required for safety reasons.

DISASSEMBLY

Step 4. Raise and support the vehicle.

Step 5. Loosen the factory exhaust at the 2 bolt flange (2) 10 mm bolts.

Step 6. Loosen clamp at slip fit connection point (behind the 2 bolt flange connection point) and remove the front section of pipe with resonator between the 2 bolt flange connection and slip joint.

Step 7. Remove exhaust from all hangers then remove from truck.

Step 8. Remove skid plate on left side of transmission cross member, (4) 8mm bolts.

Step 9. The following instructions are required only if you are planning to save the factory exhaust, otherwise skip to line #18.

Step 10. Remove (12) 10 mm bolts from front drive shaft and remove.

Step 11. Remove (2) 6 mm bolts holding left and right heat shields to transmission cross member

Step 12. Support transmission and transfer case with jack stands.

Step 13. Remove (2) 12 mm nuts from transmission mount.

Step 14. Remove (4) 12 mm bolts and nuts from cross member and remove cross member.

Step 15. Remove (1) 10 mm bolt from left Y-pipe hanger.

Step 16. Loosen clamp on left head pipe.

Step 17. Unplug all O2 sensors.

Step 18. Remove (2) 10mm nuts from left and (2) 10 mm nuts from right head pipes and remove head pipes.

Step 19. Reinstall cross member and mount and tighten.

Step 20. If you are not planning to save the old exhaust, you can simply cut hangers from Y-pipe to simplify removal of manifold pipes.

Step 21. Remove remaining (2) 6 mm bolts from right heat shield and slide heat shield back toward the rear of the vehicle.

Step 22. Remove starter and wires (1) 6 mm nut (2) nuts and (3) 8 mm bolts.

Step 23. Remove right and left heat shields on manifolds (3) 6 mm bolts two per side.

Step 24. Remove (16) 10 mm nuts, eight per side from manifolds and remove manifolds.

Step 25. Remove all (16) 10 mm studs from heads.

Step 26. Seal headers with RTV, allow the RTV to get tacky (about 15 minutes) and install using remaining studs and nuts. Torque to OEM specifications.

Step 27. Re-install starter.

Step 28. Re-install right heat shield.

Step 29. Re-install (1) 6 mm bolt back in left heat shield at cross member.

Step 30. Install left lead pipe to header with (1) 3” clamp.

Step 31. Install catalytic converter or cat eliminator to left lead pipe.

Step 32. Install rear left lead pipe to cat with 3” clamp with wire hanger.

Step 33. Re-install left hanger to transmission grommet with (1) 3” clamp.

Step 34. Install right catalytic converter or cat eliminator to header with one 3” clamp.

Step 35. Re-install all skid plates.

Step 36. Remove O2 sensors from old pipes and re-install in new pipes. Note that an O2 extension is provided for use with the left and right rear O2 sensors- install now. These sensors will have the two external nubs removed from the male end. You may have to file off the two nubs on the male end of the mating male wire end so it can slip into the female end of this extension.

Step 37. Install and secure the wires away from the driveshaft using zip ties.

Step 38. Re-install all skid plates.

FOR HEADERS TO FACTORY EXHAUST

Step 39. Install Y-pipe using (2) 3” clamps.

Step 40. Reconnect to factory exhaust using 2 1/2” clamp.

FOR HEADERS TO STAINLESS WORKS EXHAUST

Step 41. Install X-pipe using (2) 3” clamps.

Step 42. Then follow instruction for catback installation omitting Y-pipe installation in the cat back.

Step 43. Reconnect battery. Be sure to have adequate clearance around all wires, hoses and lines. If anything is in contact with the exhaust system, it will melt. Make sure to have at least ½” of clearance and wrap any suspect areas with DEI thermal barrier wrap.

Step 44. After double checking for clearance and making sure all lines, wires and hoses are secured, drive the car for 10-20 miles and re-check all clamps and clearances. Your system maybe tack welded at the joints/clamps to reduce shifting of the system during heating and cooling cycles. Make certain to disconnect the battery before performing any welding.