Stainless Works Dodge Challenger 5.7L / 6.1L / 6.4L 2008-14 Headers - Manual

2008+ SRT8/ RT CHALLENGER HEADER INSTALLATION
INSTRUCTIONS
Thanks for purchasing Stainless Works Muscleflow Headers for your SRT8/ RT Challenger. We
have gone to great pains to make sure that our systems fit and sound great. Please follow these
steps to ensure that your installation goes as planned.
Exhaust Manifold Removal
1. Let car cool completely and allow exhaust to cool completely to the touch before starting
any work.
2. Disconnect battery.
3. Raise and support vehicle.
4. Remove (2) 13mm bolts holding left rear tailpipe on and remove from hangers, then
remove pipe.
5. Loosen 2 clamps at the front of the X-pipe and the remaining hangers on system. This
may require some force to separate at clamped area.
6. Remove the (4) 13 mm bolts at tail pipe hangers and remove hangers.
7. Remove (4) 10 mm bolts holding engine service cover on.
8. Disconnect and remove all four O2 sensors.
9. Remove (4) 16mm flange bolts and remove factory lead pipes.
10. Mark steering shaft so it can be replaced in the same location and remove 10 mm and 12
mm bolts from steering shaft and remove shaft.
11. Remove (2) 10 mm bolts that hold dipstick tube to valve cover and remove dipstick tube.
12. Remove all (16) 8mm bolts that hold exhaust manifolds on and remove manifolds and
gaskets.
Header Installation
1. Apply high temp silicone (RTV) to mating surface of headers and install headers using
(16) 8mm bolts and tighten to OEM specs.
2. Re-install steering shaft, noting its proper alignment using 10 mm and 12 mm bolts.
3. Re-install dipstick tube and tighten (2) 10mm bolts.
4. Install 3” lead pipes using silicone and (2) 3” clamps.
5. Use two 3” clamps and 6” long, 3” ID x 2.75” OD adapters, slip adapters over lead pipes.
Slip 2-3/4” clamps over rear of adapters and slide adapters into factory X-pipe or
Stainless Works adapters for the catback. (Use the 2-3/4” adapters and clamps for an
SRT8 or 2-1/2” adapters and clamps for an RT).
6. Adjust and tighten all clamps.
7. Re-install O2 sensors using supplied extensions, (1) #109209 10” long for right side
header (front O2) and (2) #109209 10” long for rear 02 sensors.
8. Be sure to have adequate clearance around all wires, hoses and lines. If anything is in
contact with the system, it will melt. Make sure to have at least ½” of clearance and
wrap any suspect areas with DEI thermal barrier wrap.
9. 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.
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