Decided to install some long tube ****** headers and dual exhaust to my 96 Tahoe and i am just showing what i did and what it cost. The exaust dumps before the rear axle so these most likely aren't street/emissions legal so don't do this if you want to remain on the street.
Supplies:
Ratchet
Wrench
Drill
Welder
Grinder
Tubing bender (local muffler shop)
$50 5' Straight Stainless 2.5" Exhaust from ebay
$70 2.5" Mufflers off of ebay
$235 ****** 2462HKR Competition Ceramic Header
$40 Collecters http://www.jegs.com/i/******+Headers/520/11026/10002/-1
$7 18mmx1.5 bungs for o2 sensors
$16 EGR Plug for intake manifoldhttp://www.summitracing.com/parts/NAL-12556596/
$64 U-bend 2.5" exhaust
$40 extenders to extend the 02 sensorshttp://www.jegs.com/i/Caspers+Electronics/182/109011/10002/-1
$20 Exhaust clamps and exhaust mounts
$20 Tube bending at local muffler shop
GRAND TOTAL: $562/w normal exhaust extended over rear axle probably $700
1) Unplug your spark plug wires and unbolt the brackets that hold them on the side of the head (headers get in the way of bracket and need to be modded). Remove air intake. Unplug the coolant sensor in the drivers side head. Unbolt the oil dipstick tube and remove it.
2) Remove EGR... This would not move on the header so I thought I could remove the intake manifold connection and pull it down and out with the header but nope. I decided to cut the EGR in half and then I could pull it out with the header (my new headers didnt come with an egr port). Put the EGR block off in the intake manifold hole.
3) Unbolt your exhaust to header flange and unplug the o2 sensors. Unbolt the rear exhaust and unplug the rear o2 sensors. Cut your old exhaust to get it out unless you know a different way I could figure out.
4) Unbolt your stock headers.
5) Chase the threads in your head with a tap and make sure the bolt holes are clean.
6) Put new headers in and bolt them down working from side to side starting in the middle... Torque all the bolts snug and go to around 25 ft lbs after that. It can get hard to fit a torque wrench in there so go with allen bolts or star drive and that makes it a little easier. Otherwise torque it down with a wrench as best as you can.
7) Cut the 5' straight pipe in half and weld the reducer to each one. Connect these to your header collector and mark the location of where you want the o2 sensors in the reducers (Should be close to the collector and towards the top). Pull them out and drill a hole in the location that you marked. Weld in your bungs.
8) This is one of the hang ups; the straight pipe on the drivers side runs into the transfer case so it has to be taken to a muffler shop and they will bend it for cheap usually.
9) Clamp the mufflers down. Cut the one bend tube at the middle of the bend and it will go out right in front of the rear tire; OR get the components to finish the tubes over the rear axle. I hung the mufflers with some hangers from oreillys on bolts coming off the tahoe (seat bolts?)...
I didn't get a tune and the car runs strong. Problems i had were with the heat (i put on some header wrap and its good now) and i had a cracked spark plug that was a PITA to track down. I also should say I definitely shouldn't have skimped on the mufflers cause the ones i have dont resonate that well (its probably also the lack of pipe over the rear)
Supplies:
Ratchet
Wrench
Drill
Welder
Grinder
Tubing bender (local muffler shop)
$50 5' Straight Stainless 2.5" Exhaust from ebay
$70 2.5" Mufflers off of ebay
$235 ****** 2462HKR Competition Ceramic Header
$40 Collecters http://www.jegs.com/i/******+Headers/520/11026/10002/-1
$7 18mmx1.5 bungs for o2 sensors
$16 EGR Plug for intake manifoldhttp://www.summitracing.com/parts/NAL-12556596/
$64 U-bend 2.5" exhaust
$40 extenders to extend the 02 sensorshttp://www.jegs.com/i/Caspers+Electronics/182/109011/10002/-1
$20 Exhaust clamps and exhaust mounts
$20 Tube bending at local muffler shop
GRAND TOTAL: $562/w normal exhaust extended over rear axle probably $700
1) Unplug your spark plug wires and unbolt the brackets that hold them on the side of the head (headers get in the way of bracket and need to be modded). Remove air intake. Unplug the coolant sensor in the drivers side head. Unbolt the oil dipstick tube and remove it.
2) Remove EGR... This would not move on the header so I thought I could remove the intake manifold connection and pull it down and out with the header but nope. I decided to cut the EGR in half and then I could pull it out with the header (my new headers didnt come with an egr port). Put the EGR block off in the intake manifold hole.
3) Unbolt your exhaust to header flange and unplug the o2 sensors. Unbolt the rear exhaust and unplug the rear o2 sensors. Cut your old exhaust to get it out unless you know a different way I could figure out.
4) Unbolt your stock headers.
5) Chase the threads in your head with a tap and make sure the bolt holes are clean.
6) Put new headers in and bolt them down working from side to side starting in the middle... Torque all the bolts snug and go to around 25 ft lbs after that. It can get hard to fit a torque wrench in there so go with allen bolts or star drive and that makes it a little easier. Otherwise torque it down with a wrench as best as you can.
7) Cut the 5' straight pipe in half and weld the reducer to each one. Connect these to your header collector and mark the location of where you want the o2 sensors in the reducers (Should be close to the collector and towards the top). Pull them out and drill a hole in the location that you marked. Weld in your bungs.
8) This is one of the hang ups; the straight pipe on the drivers side runs into the transfer case so it has to be taken to a muffler shop and they will bend it for cheap usually.
9) Clamp the mufflers down. Cut the one bend tube at the middle of the bend and it will go out right in front of the rear tire; OR get the components to finish the tubes over the rear axle. I hung the mufflers with some hangers from oreillys on bolts coming off the tahoe (seat bolts?)...
I didn't get a tune and the car runs strong. Problems i had were with the heat (i put on some header wrap and its good now) and i had a cracked spark plug that was a PITA to track down. I also should say I definitely shouldn't have skimped on the mufflers cause the ones i have dont resonate that well (its probably also the lack of pipe over the rear)
. i will probably just get heat shield if it is much of a problem
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