Stainless Works Ford F-150 2004-08 5.4L Headers - Manual

2004-2008 FORD F-150 5.4L 2WD/ 4WD
HEADER INSTALLATION INSTRUCTIONS
Thanks for purchasing Stainless Works Muscleflow headers for your 2004-2008 2WD/
4WD F-150 5.4L SUPERCAB with 6.5’ bed or SUPERCREW with 5.5’ or 6.5’ bed. We
have gone to great pains to make sure that our exhaust systems fit and sound great.
Please follow these steps to ensure that your installation goes as planned.
1. Stainless Works recommends the use of Hi-Temp RTV sensor safe silicon gasket
maker as an option to or in conjunction with the use of factory gaskets. The
recommended Oxygen Sensor Safe RTV is either Valco All-in-One Aluminum or
Permatex Copper P/N 101BR, available at NAPA, Autozone 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.
DISASSEMBLY
4. Raise and support vehicle.
5. Disconnect battery.
6. Support vehicle and remove right front tire.
7. Remove screws and push pins holding inner fender on and remove inner fender.
8. Disassemble double wide clamp at rear of Y-Pipe. Keep this clamp as it is used
for reconnection to factory exhaust. (It is not needed if connecting to Stainless
Works True Dual Exhaust.)
9. Remove the hangers from the rubber insulators and remove the exhaust. If using
a lift, the exhaust can be removed in one piece, but if not, the tailpipe may need to
be cut in half for removal.
10. Remove (4) 8mm bolts holding rear skid plate on.
11. Remove (4) 8 mm bolts holding front skid plate.