Stainless Works Pontiac GTO 2005-2006 Headers - Manual

2005/2006 GTO HEADER INSTALLATION INSTRUCTIONS
Thanks for purchasing Stainless Works headers for your GTO. We have gone to great pains to
make sure that our headers fit and perform flawlessly. Please follow these steps to ensure that
your installation goes as planned. The factory manifold bolts can be re-used and we recommend
using new GM manifold gaskets.
1. Remove factory manifolds and lead pipes back to the factory two-bolt flange. Disconnect
O2 sensors before removing from car. We also recommend disconnecting the battery. In
order to install Stainless Works long tube headers, it will be necessary to drop the steering
rack and steering shaft in order to install the driver’s side header. Mark the rack and the
frame so that the marks can be lined up for proper steering alignment at re-assembly.
Disconnect the two hard lines for the power steering, and lower the rack out of the way.
2. Install headers by inserting both in from the bottom.
3. Install the factory gaskets in between header flange and block. Tighten bolts holding
flange onto head to factory torque specs.
4. One thing that you may have to do when installing headers is to center the rack/steering
shaft in the header opening. Due to production variances and tolerance stack ups, we have
seen variances car to car that make moving the rack so that the steering shaft is centered in
the header opening necessary. To do this, first make sure that the header is installed with
the gasket and all bolts tight. Loosen the rack mounting bolts and slide the rack over to the
passenger or drivers side as necessary. You may also have to bend a retaining clip on the
steering shaft out of the way for proper clearance. Spin the steering to full lock both ways
and make sure to have adequate clearance-if not, readjust the rack as necessary. Once this
is completed the steering wheel will not be centered. With the front of the vehicle off the
ground, center the steering wheel and then spin both tie rods the exact same number of
turns (one clockwise and the other counterclockwise), until the steering wheel is perfectly
straight and the front wheels are perfectly straight. DO NOT DRIVE THE VEHICLE IF
THE STEERING SHAFT IS CONTACTING THE HEADER!
5. Install O2 sensors with never-seize on the threads-be sure not to touch or get never seize on
the O2 element. Connect the O2 sensor harness using the supplied O2 harness extensions.
6. If using off road pipes, the rear O2 sensors will need to be turned off using a software
program such as LS1 edit.
7. After trial fitting the off road pipes (or catalytic converters), and rear pipes, cut four small
¼-1/2” deep grooves with a fine tooth hacksaw blade on the expanded (outer) pipe to allow
the pipe to compress and seal on the mating pipe. Deburr each piece after notching to
ensure easy assembly.