Ford Mustang BBK Headers - How To Install '05-'07 Headers

Unbolt the starter to allow the passenger-side manifold to come out. Remove three bolts and it drops right down from the bellhousing. It doesn't need to be disconnected electrically and totally removed. Once unbolted, there's enough room to remove the manifold with the starter out of the way.

As with the driver-side, the passenger-side manifold comes right off once all the fasteners are removed.

Compare the stock passenger-side manifold with the passenger-side BBK header, and it's clear the BBK piece will free up exhaust flow by a good margin. While not a totally equal-length design, the BBK header is obviously much more "equal length" in nature than the stock manifold. All the tubes on the BBK header are as equal in length as space permits, while the stock manifold isn't configured that way at all.

The oxygen sensor needs to removed from the factory manifold and reinstalled on the driver-side BBK header.

The headers and new gaskets fit in place of the stock manifolds. Although BBK supplies a complete set of header bolts, it may be easier to reuse some of the original stud-type hardware, however the header tubes won't allow the factory stud and nut to fit in some areas. Also, the stud hardware makes it easier to position the headers correctly because the studs help locate the headers. At that point, you can simply thread the nuts onto the studs, then start the header bolts in other locations once the header is in place.

There might be an instance where a stud needs to be removed to fit the header because it either didn't come off with its nut or it can't be turned by hand. It's not a problem: The factory studs are equipped with a hex head that allows them to be removed with the correct-size socket.

With the motor mount and starter out of the way, the passenger-side header also installs directly into place. Once the headers are securely bolted to the engine, everything goes back together in reverse order. This includes reinstalling the starter, motor mounts, steering shaft, dipstick tube, and H-pipe.

Reinstall the H-pipe and plug the oxygen sensors back into place to complete the job.