Stainless Works Chevy Silverado/GMC Sierra 3/4 Ton 2004-07 Headers - Manual

WWW.STAINLESSWORKS.NET 800-878-3635 FAX: 440-543-9183
2002-2007 CHEVY/GMC 8.1L TRUCK HEADERS
INSTALLATION INSTRUCTIONS
Thanks for purchasing Stainless Works Muscleflow Headers for your 02-07 Chevy/GMC
8.1L Truck. We have gone to great pains to make sure that our header systems fit and
sound great. Please follow these steps to ensure that your installation goes as planned.
DISASSEMBLY
1. Stainless Works recommends the use of Permatex Hi-Temp RTV silicon gasket
maker as an option to or in conjunction with the use of factory gaskets. The
recommended RTV is Sensor-Safe P/N 101BR or 27BR, available at NAPA and
other retailers.
2. Disconnect the battery before starting work on the exhaust system for your
vehicle. Reconnect the battery when the job is completed.
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.
4. Remove the air intake, oil dipstick, spark plugs and wires.
5. Raise the vehicle and support as necessary.
6. On the driver side leadpipe, cut the 3” factory clamp and grind down the spot
weld. On the passenger side leadpipe, remove bolts that connect it to the rear
pipes.
7. Remove transmission cross member (4 – 18mm bolts and 2 – 15 mm bolts).
Make sure to support the transmission by the transfer case using a jack or
jackstands.
8. Remove the rubber from the hanger that holds the leadpipes together, then remove
the hanger that is bolted to the transmission.
9. Remove the two O2 sensors from the leadpipes using 7/8” wrench. Remove the
lead pipes from the manifolds (6 – 15 mm bolts, 3 on each side).