Another Exhaust Thread haha aFe headers w/cat + Y pipe.

3) You'll more then likely will have to cut some of the pipe in order to use existing exhaust hangers. I cut approximately 13.5". Keep in mind I have double cab short bed but even with DC long bed I bet you'll still need a pipe cutter.
4) I would get new nuts, washers. I went to ACE and got new nuts and washers for the headers. Old ones still had good thread but they were all rusted on outside.
5) You'll more importantly need new spring bolts where the muffler pipe and y-pipe extension meet. The threads were toast on the very ends of mine and they were stock and never messed with prior. No parts stores carried these spring bolts so I improvised w/o using the spring bold but rather long enough bolts washer and nuts.
6) The heat tape they included wasn't enough and also it failed to stick so you should grab more to wrap your lines that are close to the headers.

My initial fear of install was the getting the old headers off with 9 yr old truck but that was actually fairly easy. I sprayed them 2x a week for few weeks prior to install and the old nuts backed off fairly well (probably over kill but I was paranoid of braking a stud and having to pull whole engine out).

Where we ran into problems was connection point where y-pipe meets the front extension of pipe coming out of muffler. Reason being is your stock muffler pipe comes out of the center of muffler on both ends (see pix). Well most after market mufflers like aFe's the pipe comes out on one end (on left or right side). If using existing hangers (didn't want to weld the exhaust pipe or weld new hanger spots) then you'll have some finagling to do to make it fit. Because of which we bored out the threads for where the spring bolts would've been used and used new hardware (nuts, blots and washers). This gave a better seal.

I am sure there is some small details I am missing so I'll update it as needed. We installed this at my buddies house which was about 3 hours away so on the drive home after the install I noticed a bubbling sound. I inspected the connection points once I got home and saw a small amount of black suet. So be prepared to re-torque after the pipes are hot in order to get a better seal. So far I haven't had to re-torque where the header are but maybe its because I used new gaskets.

 

Out with the old (if someone is interested in old parts PM me)

 

In with the new headers

 

From the converters back to exhaust tip

 

I can't seem to upload the videos of before and after sounds so bare with me. They are under 1 min each so shouldn't be too large.

 

Here are area where suet is peaking its way out before I re-tightened it down.

 

Let me know how you like this exhaust kit. My muffler have a hole in it and I am shopping around for a complete replacement. I like that this kit gets rid of half the catalytic converters.

For sure I am expecting an answer such as "yes it is lounder than OEM" and "it kicks a**". However does it triggers any ECU codes? Any requirements for a O2 simulator kit from URD? Is the in-cab noise level remains decent?

Cheers, and great work on the installation!

 

Would love to hear this set up! Any videos on youtube or anything? This is the exact exhaust I am looking at.

 

First video is better one. This is sound of the TRD Supercharger "whine" with the aFe Cold Air Intake prior to installing headers and exhaust.

 

Here is another before video but I couldn't get up to speed due to traffic.

I typically shift b/w 1500 & 2000 RPMs but for purpose of the video I wanted to give you all better range of the sound. Therefore I shifted b/w 3000-5500 RPM's but I still didn't floor it each time.

Sorry for the poor video quality and operator error amongst the pitted windshield, glare & the jingle of my keys dangling in all these videos.

 

This with the headers, y-pipe and 3" exhaust. You can still hear the whine of the charger but now the added growl of exhaust. Hope you all enjoy!

 

Lot of glare & pitted windshield in this vid but another version of sound with the headers and exhaust.



Sorry for the long delay in getting this videos uploaded, thanks for your patience. Happy Independence day to you all!

 

Did the removal of the secondary cats trigger any codes?

 

The truck don't know anything about the 2nd cats, they are behind the 2nd O2 sensors.

 

About 2 weeks after install my check engine & VSC light came on. I called aFe to get their opinion. I also talked to UDR can the conclusion is to buy O2 Simulator. I ordered it few days ago.

http://urdusa.com/store/Electronics...1GR-FE-4.0L-V6-Dual-Channel/product_info.html

 

Interesting, aFe claims that it should not trigger any ECU codes on their product page...

Well regardeless, I will more than likely buy those headers/y-pipes. However I will remain conservative with a 2.5in exhaust instead of the 3in. I do not have forced induction and do not plan to acquire. This should keep the setup a bit quieter.

 

If the cats work like they should, there should be any codes.

What was the code?

 

Since the new cats are high flow, the rear sensors have a much different reading since it compares the pre cats reading with the output at the rear O2 sensors. The flow can be out of specs over OEM, triggering the code.

 

Exactly!

Now theoretically there shouldn't be codes according to aFe but every application is different. Not sure if its combo with S/C or what but either way hopefully the O2 simulator resolves it. Sucks to have to spend another $150+ but it is what it is