BBK 40150 Shorty Headers Instruction Manual

: June 13, 2024
: BBK

Table of Contents

INSTALLATION INSTRUCTIONS
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BBK 40150 Shorty Headers Instruction Manual

INSTALLATION INSTRUCTIONS

SHORTY HEADERS
PART #4015 – DODGE RAM 1500 5.7L HEMI 1-3/4 IN. SHORTY HEADERS – TITANIUM CERAMIC (19 22)
PART #40150 – DODGE RAM 1500 5.7L HEMI 1-3/4 IN. SHORTY HEADERS – POLISHED SILVER CERAMIC (19-22)

VEHICLE FITMENT:

2019-2022 Dodge Ram 5.7L 1500 ONLY (Excluding MegaCab)
Does NOT fit 2500 or 3500 models due to limited engine mount clearance
These Headers Fit ALL 2WD & 4WD applications

TOOLS NEEDED: Flathead Screwdriver, Wrenches, Rachect Wrench with extension, sockets (mm) – 8, 10, 13, 14, 15, 16, 18, & 9/16
INSTALLATION TIME: Aproximately 6-8 hours
DIFFICULTY RATING: Moderate

IMPORTANT WARRANTY INFORMATION:
INSTALLING ANY TYPE OF
EXHAUST HEADER WRAP
ON BBK EXHAUST HEADERS
WILL VOID YOUR BBK WARRANTY

IMPORTANT : All appropriate safety equipment and gear must be used during the installation of this or any BBK Perfomance products or any time you work on a vehicle. BBK accepts no responsibility for injuries or damage cause by or during the installation of this product.

Start with the vehicle on the ground with the hood raised (a step ladder is a valuable tool).
Disconnect the battery.
Remove the factory intake air box and tube to throttle body.
Remove the factory power brake booster vacuum pump.
Remove the steering shaft bolt and pull the shaft away.
Remove oil dipstick bolt and push the dipstick to one side (no need to remove).
Remove the heat shields on passenger and drivers side headers
Move around to the passenger wheel on the outside of the truck and remove the inner fender liner pull out and away from the vehicle – this will now give you great access to remove and install the headers.
On passenger side disconnect the heater hose brackets and lay the hoses on the valve covers – These hoses will be wrapped with the supplied heat wrap and zip ties for extra protection covered in Step 29.
While you are here disconnect all fasteners that hold the passenger side ABS sensor wires to the frame and leave it loose for now – we will be coming back to this later
It’s now time to get the truck in the air.
Support the transmission with a jack.
Remove the skid plate (4WD Only).
Remove the nuts and bolts from the transmission crossmember and remove the crossmember.
Remove the nuts that attach the cat back exhaust to the Y-pipe on the passenger side.
Using a crowbar or large screwdriver, push back the cat back pipe approximately 2 inches.
Support the Y-Pipe & disconnect the 4 x O2 sensor harnesses from the factory harness.
Unbolt the Y-Pipe at the drivers and passenger side factory manifolds.
Remove the factory Y-Pipe.
Re-Install the factory crossmember and hardware – Temporarily ( no need to tighten).
Lower tranmission jack.
Remove all factory exhaust manifold header bolts and remove the manifolds.
Take a clean rag and some degreaser and clean the head/manifold surfaces well. Any carbon build up should be removed gently with a small putty knife – DO NOT scratch the head surface!
Now move to the drivers side of the truck and remove the transmission cable bracket – replace with the supplied BBK Bracket and clamp as shown.
Before installation of your new BBK Headers a simple trick to ease the header gasket installation is to take some electrical tape and tape the gasket in place as shown – tape can be removed after the bolts are loosely in place if you tape it right!
GASKET INSTALLATION NOTE: CHECK THAT THE GASKETS ARE INSTALLED CORRECTLY! The passenger side header and gasket have an EGR port cutout. Reversing these gaskets WILL CAUSE GASKET BLOWOUT.
Now its time to install your new BBK exhaust headers with the supplied hardware – PLEASE NOTE: DO NOT wrap your BBK exhaust headers – this will void your warranty and cause premature failure
Torque all the header bolts where possible to factory spec with a wrench or socket – this is not possible in most cases but it should be around 18-20 ft lbs or TIGHT – use your good judgement. Don’t forget to re-install the dipstick using the supplied 8mm long bolt and spacer. Important: to prevent gasket leaks and blown header gaskets you MUST retorque all header bolts after a couple of heat cycles or a few hundred miles after installation.
Please note Before – reinstalling the inner fender cover on the passenger side make sure to install the ABS wire as shown in the photo with the supplied BBK ABS zip tie. This is for heat protection – be sure to re-route the wire behind the A-Arm as shown and zip tie to the brake line – also use supplied heat wrap/wire ties to protect heater hoses if you have not already done so. After heater hoses are wrapped, run a couple of zipties thru the coil packs to lift hoses away from header for heat protection
To complete the installation of the rest of the components, it is now a reverse of previous steps starting by reinstalling the Y-pipe.
Reconnect battery and enjoy the additional performance and great sound of your new BBK Headers!