Nitrosanity
New member
Hoping to install mine soon, just got off phone with Jason seems we have a 6-8 week waiting period currently
!!Doug Thorley Headers 4.7L V8!!
- Thread starter BootyFister
- Start date
Ida4runner
New member
I have a new set for a 03-05 if anyone is interested in the classifieds.
03-05 4.7 v8 Doug Thorley Headers
03-05 4.7 v8 Doug Thorley Headers
so with URD looking like they no longer offer the o2 simulator.... does anybody have any leads on any other options that we may have in case you don't want to be running a high flow cat ? Or are we back down to having to install a high flow cat in order not to get a CEL after a header job?
my bank 2 cat is on its way out, i have a temporary fix with an o2 spacers that works here and there, but long term I'm just waiting for the headers to crack or the other cat to go out as well and would ideally not want to spend 600 bucks on an aftermarket catalytic header that will just fail a couple of years down the road.. I'd love to throw in a set of these headers and I guess if an o2 simulator is no longer an option would look into doing a high flow cat in hopes of making it work with the o2 sensor/spacer combo.
my bank 2 cat is on its way out, i have a temporary fix with an o2 spacers that works here and there, but long term I'm just waiting for the headers to crack or the other cat to go out as well and would ideally not want to spend 600 bucks on an aftermarket catalytic header that will just fail a couple of years down the road.. I'd love to throw in a set of these headers and I guess if an o2 simulator is no longer an option would look into doing a high flow cat in hopes of making it work with the o2 sensor/spacer combo.
Ida4runner
New member
....
K-D-Runner
New member
On my 04 I had the long tubes and a set of 02 spacers from burtman industries to get away with no CEL. Easy solution that works for most. Basically just pushes the sensor further from the flow of gasses so the gasses seem less rich, just enough to not throw any red flags. I passed emissions and everything.
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Thanks for the feedback, thats pretty interesting.. I know of the spacing method and I'm currently running this fix on my stock setup because my bank2 cat is starting to go. However, what I found was that there is definitely a sweet spot of how far you want to space it out.. it needs to be far enough out to make sure its not picking up too much flow, but it also needs some flow throughout the RPM range because I got rid of the CEL for the cat really easy, but then started throwing intermittent CEL for the O2 sensor having a short (since it was too far out and would not change the reading at low RPM).
Jason B
Official Vendor
:thumb: Glad you got it all on.
Titanium Stud kit at Burtman Industries - This saves 1.5 - 2 hours on the install!
Also, here are the links to the headers themselves. There is a PRICE increase come MARCH, so if anyone is on the fence order links below.
03-04 Doug Thorley headers at Burtman Industries
05-09 Doug Thorley headers at Burtman Industries
Before install showing the long tubes and studs. Very pretty. Any questions, call/text 717-319-2100
Burtman Industries Titanium Studs & Doug Thorley Headers/Y pipe - YouTube
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I have this issue as well. It's not serious enough to look at aftermarket solutions. My exhaust place says, be careful about fitment issues and getting the old manifolds out.
He generally just welds the cracks and most of the work is related to heat shields etc. He does custom fabrication. You can get the side that's ticking welded. There is no issue with performance or mpg at this point. It's a V8 Runner after all
He generally just welds the cracks and most of the work is related to heat shields etc. He does custom fabrication. You can get the side that's ticking welded. There is no issue with performance or mpg at this point. It's a V8 Runner after all
Hey all
Noob here. I’ve installed the long tube headers and used spacers on the downstream O2 sensor. The guy installing them said I’m now getting some type of overflow code for the upstream sensor. I’m scrounging for an O2 simulator but in the instance I can’t find one is the solution to use spacers on the upstream sensors?
Noob here. I’ve installed the long tube headers and used spacers on the downstream O2 sensor. The guy installing them said I’m now getting some type of overflow code for the upstream sensor. I’m scrounging for an O2 simulator but in the instance I can’t find one is the solution to use spacers on the upstream sensors?
4RunnerAquasport
Senior Member
No, the upstream units are air/fuel ratio sensors. They need to stay seated all the way into the headers.
Ask him what the code number is and post it up here.
Hopefully someone with experience w these codes can help.
My AF sensors have been working fine. The only problems I had were w the o2 sensors (downstream) throwing their related codes, with spacers installed.
URD used to sell an o2 sensor simulator, but the emissions police were making it difficult for him to sell these units any longer. There are mini cats out there that will help eliminate o2 codes, but are ugh...illegal SMDH.
You could put high flow cats in, that are legal, but will cost you a left nut AND a first born.
If all the other pieces of the puzzle (MAF sensor, fuel injectors, intake plenum, air filter, new plugs??) are working properly, the AF sensors should hopefully be working as they were designed, seated all the way in the headers.
You could possibly have a faulty AF sensor or related circuitry.
I do recall a lean condition early on after my header install, which stumped me for a few minutes, but I found a vacuum line that had come loose, which allowed too much air flow.
When doing header exhaust modifications, it really helps to have a code reader and learning about all the different problems that can arise. That way you can avoid having to go to the shop or a parts store every time a code pops up.
There is a wealth of knowledge about these subjects in this forum and others online.
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AboLetsGo
New member
Problem with doug thorley shorty headers and looking for some advice
So basically, I had my exhaust system built around the DT shorty headers back in 2017. I deleted the 2 down stream cats and had magna flow stainless steel high flow cats welded onto the headers. Custom pipes into a "y" flanged to accept a stainless steel magna flow cat back. It's been great up until about 2 weeks ago when I started to hear an exhaust leak that sounded similar (but way worse) to the *putt putt putt* from the old cracked stock manifolds.
I hunted around for the problem and removed the mud covers from the wheel to expose the headers and saw, to my total surprise, that the SAIS tubes were totally rusted out as well as the flanges having massive corrosion. That is when I realized that these "stainless steel headers" are only stainless collection tubes with normal everything else. I checked my receipt and install manual and all it said was "304 stainless steel construction". WTF?
I called Doug Thorley to bring this to their attention only to be told their warranty doesn't cover rust. My issue is that I thought I was buying stainless steel headers as per their item description but the flanges and SAIS pipes are mild steel so I figured since they failed after 5 years their lifetime warranty would cover that. Well, it doesn't and now my 4runner is looking at a massive repair bill and having to buy those headers again which now include stainless steel SAIS pipes.
I've been speaking with DT for a little over a week and they really aren't budging on the issue and actually want me to remove the headers and send them back to them at my expense, which will cost around $600 to have them removed (dealing with serious back injury) plus shipping to see if they can repair them. I don't know what kind of repair can be made on these since the sais pipes are rusted through and the flanges leak. Then i'll have to pay to have them reinstalled which cost around $1300 last time around.
I would honestly just settle for them giving me a new pair that at least have stainless SAIS pipes which are rusted out on mine and just sucking it up and paying to have them reinstalled but according to them that is not an option.
If anyone can give me any sort of insight or advice as to what I should or can do about this I am all ears. I'm not incredibly happy about their proposed resolution to the issue as they gave me 2 options: send them back and see if they can repair them at my expense (around $600 plus reinstall. I'm not the least bit convinced these rusted out headers can be "fixed")or buy a new pair at the price I paid originally which was close to $800, plus cats and install of the new set up.
So basically, I had my exhaust system built around the DT shorty headers back in 2017. I deleted the 2 down stream cats and had magna flow stainless steel high flow cats welded onto the headers. Custom pipes into a "y" flanged to accept a stainless steel magna flow cat back. It's been great up until about 2 weeks ago when I started to hear an exhaust leak that sounded similar (but way worse) to the *putt putt putt* from the old cracked stock manifolds.
I hunted around for the problem and removed the mud covers from the wheel to expose the headers and saw, to my total surprise, that the SAIS tubes were totally rusted out as well as the flanges having massive corrosion. That is when I realized that these "stainless steel headers" are only stainless collection tubes with normal everything else. I checked my receipt and install manual and all it said was "304 stainless steel construction". WTF?
I called Doug Thorley to bring this to their attention only to be told their warranty doesn't cover rust. My issue is that I thought I was buying stainless steel headers as per their item description but the flanges and SAIS pipes are mild steel so I figured since they failed after 5 years their lifetime warranty would cover that. Well, it doesn't and now my 4runner is looking at a massive repair bill and having to buy those headers again which now include stainless steel SAIS pipes.
I've been speaking with DT for a little over a week and they really aren't budging on the issue and actually want me to remove the headers and send them back to them at my expense, which will cost around $600 to have them removed (dealing with serious back injury) plus shipping to see if they can repair them. I don't know what kind of repair can be made on these since the sais pipes are rusted through and the flanges leak. Then i'll have to pay to have them reinstalled which cost around $1300 last time around.
I would honestly just settle for them giving me a new pair that at least have stainless SAIS pipes which are rusted out on mine and just sucking it up and paying to have them reinstalled but according to them that is not an option.
If anyone can give me any sort of insight or advice as to what I should or can do about this I am all ears. I'm not incredibly happy about their proposed resolution to the issue as they gave me 2 options: send them back and see if they can repair them at my expense (around $600 plus reinstall. I'm not the least bit convinced these rusted out headers can be "fixed")or buy a new pair at the price I paid originally which was close to $800, plus cats and install of the new set up.
moshrider3
New member
I was just quoted by a dealership only because I was curious what they’d charge to change both exhaust manifolds and they told me $5,000
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AboLetsGo
New member
Mine would be much more as I have a bad SAIS pump and cat delete for the down streams. My exhaust system was built around these headers and the SAIS block offs with cat deletes. I'm also running an 02 simulator to kill the codes and CEL.
I read an old thread by user Marfy from 2019 where he had the same issue and they gave him a new set but Jen from DT told me Mike didn't have upper-management authorization to do warranty exchanges for the rusting headers. In the email Marfy posted the sales manager even said that anyone with rusting SAIS pipes would be covered. They started making them out of stainless after that debacle but a lot of people are stuck with these rusting away since they aren't actually stainless.
Funny enough after my week long hammering on how they advertise them as stainless when they aren't they changed the item description on their website to include "mild steel flanges". Well, mine are mild steel flanges AND SAIS pipes which are totally rusted out.
I read an old thread by user Marfy from 2019 where he had the same issue and they gave him a new set but Jen from DT told me Mike didn't have upper-management authorization to do warranty exchanges for the rusting headers. In the email Marfy posted the sales manager even said that anyone with rusting SAIS pipes would be covered. They started making them out of stainless after that debacle but a lot of people are stuck with these rusting away since they aren't actually stainless.
Funny enough after my week long hammering on how they advertise them as stainless when they aren't they changed the item description on their website to include "mild steel flanges". Well, mine are mild steel flanges AND SAIS pipes which are totally rusted out.
AuSeeker
Elite Member
If you have a receipt that states "stainless steel construction" and says nothing about mild steel, it would also help if you could find a screen shot of the old description from their website and then maybe you should contact a lawyer, or at the very least tell Doug Thorley that they will be hearing from your lawyer and see if that light a fire under their a$$!!
AboLetsGo
New member
I have screen shots of their website from before they changed it. I'm not really trying to threaten anyone with a law-suit as I think that's ridiculous and this is clearly a case of "yea we fudged up on that production run so here is a set of the ones after we fixed our mistake". I think any reputable company would do that and DT has done that because of this exact same issue with these exact same headers for other customers.
I didn't even want to post anything online about the issue as I didn't want to seem like some disgruntled whiner but I can't be the only one with this issue and DT isn't really making it easy.
AuSeeker
Elite Member
I don't take lawsuits lightly and see them as a last resort...but when it comes down to getting a company to do what's right when they refuse to do so then it's another story!
AboLetsGo
New member
I didn't mean to imply that you did. I just mean that if I had to go that route that it would be ridiculous. I get ya. :cheers:
I just got off the phone with a performance shop and they are going to take a look at them on Friday to see what can be done. He quoted me at 15 hours just for the removal and install with no fabrication. We are going to get it up on the lift, get some better pictures, he is going to access the damage then let me know if they are salvageable then write me up an assessment that I can send to DT since they want me to ship them back at my expense. That is looking like it's going to cost more than $800 (shop time for removal + shipping) which is more than I paid for the headers. :redbrick:
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