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Custom 2004 Ford F-150 - Project Dark Horse, Part 1

 
0512St 2004 Custom Ford F150 Exhaust 09 Z
The back end of the exhaust... 
   
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0512St 2004 Custom Ford F150 Exhaust 09 Z
The back end of the exhaust manifold pipe was then unbolted.
0512St 2004 Custom Ford F150 Exhaust 10 Z
The sway bar was also unbolted... 
   
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0512St 2004 Custom Ford F150 Exhaust 10 Z
The sway bar was also unbolted and removed for extra clearance.
0512St 2004 Custom Ford F150 Exhaust 11 Z
The driver-side front exhaust... 
   
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0512St 2004 Custom Ford F150 Exhaust 11 Z
The driver-side front exhaust section was then unbolted from the manifold and the crossover pipe.
0512St 2004 Custom Ford F150 Exhaust 12 Z
Then the passenger-side front... 
   
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0512St 2004 Custom Ford F150 Exhaust 12 Z
Then the passenger-side front exhaust section was removed.
0512St 2004 Custom Ford F150 Exhaust 13 Z
For more clearance, the starter... 
   
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0512St 2004 Custom Ford F150 Exhaust 13 Z
For more clearance, the starter was also disconnected and removed.
0512St 2004 Custom Ford F150 Exhaust 14 Z
Both exhaust manifolds were... 
   
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0512St 2004 Custom Ford F150 Exhaust 14 Z
Both exhaust manifolds were then unbolted and removed.
0512St 2004 Custom Ford F150 Exhaust 15 Z
To install the passenger-side... 
   
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0512St 2004 Custom Ford F150 Exhaust 15 Z
To install the passenger-side header, the motor mount had to be removed, and the engine had to be lifted up about 1 inch.
0512St 2004 Custom Ford F150 Exhaust 16 Z
Per the included instructions,... 
   
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0512St 2004 Custom Ford F150 Exhaust 16 Z
Per the included instructions, several studs had to be removed and ground down for the headers to fit.
0512St 2004 Custom Ford F150 Exhaust 17 Z
Ed likes to apply a thin coat... 
   
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0512St 2004 Custom Ford F150 Exhaust 17 Z
Ed likes to apply a thin coat of adhesive to the gasket and around the ports on the head to ensure leak-free operation.
0512St 2004 Custom Ford F150 Exhaust 18 Z
The gasket was then slipped... 
   
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0512St 2004 Custom Ford F150 Exhaust 18 Z
The gasket was then slipped over the studs and pressed against the head ports. (Note: Clean the head surface of any carbon deposits with a scraper or wire brush before installing the gasket; luckily for us, these heads were clean.)
0512St 2004 Custom Ford F150 Exhaust 19 Z
The headers were then attached... 
   
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0512St 2004 Custom Ford F150 Exhaust 19 Z
The headers were then attached using the factory hardware and tightened in an alternating sequence to prevent bending the flange.
0512St 2004 Custom Ford F150 Exhaust 20 Z
Finally, the factory exhaust... 
   
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0512St 2004 Custom Ford F150 Exhaust 20 Z
Finally, the factory exhaust was reconnected; the motor mount was bolted up; the sway bar was installed; the starter was bolted in and connected; and the fender panels were attached.

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