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2011-2014 FORD MUSTANG

GT 5.0L FULL LENGTH

HEADERS PART# 1633/0/5

INS163

TOOLS REQUIRED-6, 8, 10, 13, 15mm socket, 8, 10, 13, 15, 22mm wrenches, ratchet, universal for sockets, various

length extensions,

You will be reusing most of the stock manifold studs for

header

installation.

Five required bolts are supplied.

STEP 1

Disconnect negative battery cable.

STEP 2

Remove air filter box. Remove the first and second nuts on the top row of studs on the stock

header on the driver side. On the passenger side, remove the first top nut that is behind the AC

hose. Use long extensions and socket to remove the outside converter pipe nut at the collector

of the stock header on the pass side. You won’t be able to access it when under the

car.

Loosen

the motor mount nuts on the studs that face up but don’t remove yet.

STEP 3

Raise car up and support on stands or place on car lift.

STEP 4

Unhook O2 sensor plugs for the front and rear O2 sensors,

STEP 5

Loosen clamps at front of stock H pipe and then loosen the barrel style clamps at the rear. These

rear clamps will be reused with the BBK X-pipe assembly. Remove stock H pipe.

STEP 6

Remove nuts on converters at the header collectors. Remove converter pipes.

STEP 7

Remove the four nuts on the round tube support brace under the oil pan and remove brace.

STEP 8

Loosen the three small bolts on the plastic cover that covers the area around and forward of the

rack and pinion. Let plastic cover hang. This will give access to front header nuts.

STEP 9

Remove the two bolts from the steering u joint at the rack and pinion, remove u-joint so shaft

can hang out of the way.

Fig. 1

STEP 10

Remove the starter.

STEP 11

With a jacking device in place under the bellhousing and a block of wood between the jack and

bellhousing,

remove the motor mount nut on the driverside, jack up engine and remove the four

bolts that secure the aluminum mount to the engine block. Remove the aluminum mount.

Fig’s 2 and 3

STEP 12

Remove all exhaust nuts and remove stock header. Remove stock gasket.

STEP 13

Remove the studs that

correspond

to the notches in the BBK header flange. You will install

supplied bolts in these spots. Fig’s 4 and 5. NOTE: There are 2 thread pitches supplied,

because the

manufacturer

changed the thread pitch used after 2011, you will have to

compare the supplied bolt to the factory stud to confirm which thread pitch to use.

STEP 14 Install gasket on remaining studs and install BBK header. You might have to raise motor a bit

more to get header to slide in place. The stock metal gasket will also work if you’d like to reuse it.

STEP 15

Install nuts and bolts and tighten.

STEP 16

Reinstall motor mount and lower engine back down, Reinstall nut on mount stud.

STEP 17

Repeat steps 11 thru 16 for passenger side. NOTE: The first notch on the passenger side

header will re-use the factory stud and the remaining notches will use the supplied bolts (2).

STEP 18

Reinstall starter, steering u-joint and shaft and round tube lower brace. Reinstall front plastic

cover.

STEP 19

Install supplied front and rear O2 sensor extension wires.

STEP 20

Remove front and rear O2 sensors. Install the front ones in the collectors of the headers, connect

to the front O2 sensor extension wires.

STEP 21

Install the supplied studs in the collector flanges.

IMPORTANT- All appropriate safety equipment and gear must be used during the installation of this or any BBK Performance products or any time you work on a vehicle. BBK

Performance Inc. accepts no responsibility for injuries or damage caused by or during the installation of this product

Revised 2/25/2013

Summary of content (6 pages)

PAGE 1
INS163 2011-2014 FORD MUSTANG GT 5.0L FULL LENGTH HEADERS PART# 1633/0/5 TOOLS REQUIRED-6, 8, 10, 13, 15mm socket, 8, 10, 13, 15, 22mm wrenches, ratchet, universal for sockets, various length extensions, You will be reusing most of the stock manifold studs for header installation. Five required bolts are supplied.
PAGE 2
STEP 22 STEP 23 STEP 24 STEP 25 STEP 26 STEP 27 STEP 28 STEP 29 STEP 30 Slide the stock barrel clamps onto the front of the stock exhaust system about halfway. Install the BBK X pipe section into the barrel clamps and then connect the front of the X pipe to the collectors of the headers. Use supplied nuts and washers to secure. Level out the X pipe and tighten the collector nuts, then tighten the barrel clamps. Install the rear O2 sensors into the bungs on the X pipe and connect the O2 sensor extensions.
PAGE 3
Fig. 1 Steering Shaft Removal. Remove shaft, then remove U-joint. Fig. 2 Motor mount removal. IMPORTANT- All appropriate safety equipment and gear must be used during the installation of this or any BBK Performance products or any time you work on a vehicle. BBK Performance Inc.
PAGE 4
Fig. 3 Motor mount removed. Fig. 4 Removing stock studs. IMPORTANT- All appropriate safety equipment and gear must be used during the installation of this or any BBK Performance products or any time you work on a vehicle. BBK Performance Inc.
PAGE 5
Fig. 5 Remove stock studs that correspond with notches in flange. Use supplied bolts. IMPORTANT- All appropriate safety equipment and gear must be used during the installation of this or any BBK Performance products or any time you work on a vehicle. BBK Performance Inc.
PAGE 6
Because your vehicle's engine is electronically controlled by a computer, some control conditions are maintained by power from the battery. When the battery is disconnected or a new battery is installed, the engine must relearn its idle and fuel trim strategy for optimum driveability and performance. To begin this process: 1.) With the vehicle at a complete stop, set the parking brake. 2.