Recent content by 200 hp

Must be welded on a bench. There is no clearance to put a 360 degree bead while installed.

The install is nearly finished. Because I used to work with him he allowed me to do the removal myself using his lift. I forgot to order new exhaust hanger rods so it set us back a few days. Having done it once I now understand the process and have the tools required. It isn't a fun job by any...

I have to admit I thought they were selling themselves short on the initial estimate but that is major BS to call and revise that much higher! My buddy in Fredericksburg said he would do it for $1500 if you run out of options.

So we finally got the old studs out and mounted the new headers for mock up. Attached are a few pics. Note about the dipstick. It is not clear in the instructions but the transmission dipstick must be completely removed from the vehicle for installation. After the header is bolted on then you...

Thank you sir. We are currently working to remove the old studs. I purchased a Gearwrench metric stud remover set and already broke two of the sockets. Also purchased an offset Powerbuilt stud removal tool and there isn't enough clearance. Last resort is to weld a nut onto it.:sniper:

I seem to have misplaced my instructions from DT. Can someone please post up a copy? I'm mostly looking for the part about the dipstick spacer.

Yes, I would be referring to A in the diagram. There should be enough clearance under there that any orientation of a 2.5" flange should be able to fit no problem.

Stock flanges are 60mm. 2.5" flanges are 63mm. Your fabricator should be able to weld a bead big enough to cover the 1.5mm difference around the piping.

More like a pushover* :whipping2

Here was my invoice: Burtman is correct that you can reuse the manifold gaskets for the 2003-2004 as they are multilayer steel but I figured what the heck my truck has 193,000 miles.

90080-12008 for the studs 90080-17187 for the nuts Both are confirmed to work for 2003-2004

I get all my OEM parts from Toyota Online Parts | toyotaonlineparts.com | Toyota Parts Online. 16 studs cost $45.44 and 16 nuts were $21.92. They're located in Richmond, VA so they get to Northern VA in one day by standard mail.

Here's a picture of the D/S header during removal: Here's some pics of the goodies: I'm having my fabricator build a custom SS T304 2.5" setup using: Magnaflow HF cats, Magnaflow 18" muffler; Vibrant Performance resonator, 2-1 collector, mandrel bends, flanges and muffler tip. I also...

Well this has been a nightmare of a job. Took me two days working straight through pretty much to remove the old headers. All 16 studs were rusted, seized and stripped as I attempted to remove them. Had to use 14mm vise grip sockets and work my way down to 13mm, 12mm, 11mm and 10mm to strip as...

Had to push my install back a week. I'll try to upload some photos of all the goodies though.