HOJeepster
New member
Yes, running 1" BL. And no, stock bolts on the steering shaft. It's definitely that area of the bolt that rubs the headers.
Installing Doug Thorley Headers on 2005 4.7L V8 w. 2" BL
- Thread starter Cpt_Romania
- Start date
Yes, running 1" BL. And no, stock bolts on the steering shaft. It's definitely that area of the bolt that rubs the headers.
That_Titanium_4RNR
New member
I am really thinking about running a 1" bl soon and especially with those tires we were talking about. I think i'm going to pull the trigger. I don't have the headers yet and when I get them I'll swap that bolt out and maybe do some extremely light "dimpling" if needed
Zero0575
Member
Success!!!
I was finally able to get the install completed. After 7 weeks of waiting and being lied to (they said they had installed the passenger side and were working on the driver side - the lie detector test determined THAT was a lie lol), I took my car elsewhere and had everything installed in a timely manner.
AND in the process I found a mechanic in Indiana that isn't a moron! But he is from California, so that might be a technicality...
Most importantly, headers installed, no denting was necesarry - 1200 mile road trip in the books and all smiles over here!
I was finally able to get the install completed. After 7 weeks of waiting and being lied to (they said they had installed the passenger side and were working on the driver side - the lie detector test determined THAT was a lie lol), I took my car elsewhere and had everything installed in a timely manner.
AND in the process I found a mechanic in Indiana that isn't a moron! But he is from California, so that might be a technicality...
Most importantly, headers installed, no denting was necesarry - 1200 mile road trip in the books and all smiles over here!
Cpt_Romania
New member
Hey congratulations! What did you do with the exhaust back from the headers?
Zero0575
Member
I used Magnaflow high flow cats (part # 59956) and also some CNT brand spacers to clear the CEL but otherwise stock to keep it refined/quiet. Being in the Midwest, most of my destinations are 500+ miles away so I wanted to keep it quiet for comfortable interstate driving to my destinations.
Took it to Tray Mountain in GA this weekend and it was a blast!
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Cpt_Romania
New member
Glad to hear! Stay safe out there!
Cpt_Romania
New member
Update 11/18/2019
Car is still running great, no problems, check engine lights, idling issues, exhaust leaks or anything of the sort.
Still getting 12.5 MPG average with my 35" Wrangler Duratracs and it does very well.
I have decided to look into installing a muffler however, because, to my surprise, I am actually starting to get a little annoyed by the cat-back straight pipe that I have on it, it was fantastic in the beginning but some life changes are making me want it a little quieter so (1) Magnaflow Muffler, maybe a exhaust tip, will be my next move.
I'll let you know how it goes from here. One of these days I'll put together a build thread for the 4runner too.
Car is still running great, no problems, check engine lights, idling issues, exhaust leaks or anything of the sort.
Still getting 12.5 MPG average with my 35" Wrangler Duratracs and it does very well.
I have decided to look into installing a muffler however, because, to my surprise, I am actually starting to get a little annoyed by the cat-back straight pipe that I have on it, it was fantastic in the beginning but some life changes are making me want it a little quieter so (1) Magnaflow Muffler, maybe a exhaust tip, will be my next move.
I'll let you know how it goes from here. One of these days I'll put together a build thread for the 4runner too.
Hello to you all,
I bring you all now the story of how I installed 05-09 Doug Thorley Headers on my 05 4Runner which has 2" BL, but not after I bought the 03-04s Headers and spent 3 months driving back and forth taking my headers off a grand total of 4 times before coming up with a solution!
Let us begin:
Exhaust tick started, tried to ignore it, it got much worse and I started to hate driving my 4runner. Found this Doug Thorley Header solution and I rationalized in my head that it was worth the money and that it will be the last mod I'll do ( Yeah right -_- )
After talking with Jason from Burtman Industries I learned that the 03-04 headers were "exactly" the same as the 05-09s except for not having an EGR tube and something else, which I'll mention later on.
I ordered the Headers, (2) Magnaflow catalytic converters and the 4.7L Air Induction Pump Bypass Kit and Exhaust Port Plates off of eBay, which you need for the 03-04s because they do not have an EGR tube.
So long story short, the 03-04s did NOT fit because of the 02 sensor bung placement on the headers, they were drilled into the bottom of the header making it impossible for my female end to fit, on top of the fact that the steering shaft was entirely in the way. This is the other difference I was talking about that neither myself or Burtman saw coming, guess that's what happens when your blazing a trail into uncharted waters and Doug Thorley said they will NOT sell their headers to people with Body Lifts :moping:
So I left my car at the shop as I tried brainstorming a solution ( the shop is 2 hrs away from my home by the way, so I had to get a ride back home ) and I came to the conclusion that the 05-09s would be the best solution since there were no solutions coming up for extending 02 sensor wires.
Obviously I couldn't return the 03-04 headers because they already had a pair of cats welded to them. Here is the post where I SOLD the 03-04 pair and there's more information there.
http://www.toyota-4runner.org/sale-...ley-magnaflow-combo-$800-portland-|-sold.html
So I got bought a set of 05-09 Headers and another set of Magnaflow Cats, had them welded up again and drove back to the shop and it still wouldn't clear the steering shaft ( we "dimpled" previously a little ) so this is where I lost my mind and took a hammer and blow torch to them until they fit
[ Also I still had the $199 4.7L Air Induction Pump Bypass Kit that you connect to your Air Intake which I didn't even "need" anymore because the 05-09 Headers come with the EGR tube so it's more of a precaution at this point in case the "computer/sensor" goes out, but I'm told it costs a lot of money to replace and if you don't your Check Engine light will stay on ) but the thing is that my check engine light will probably always be on because of one reason or another so it's just an ornament in my engine bay now ] :clap2:
Also if you want to hear what the 4runner sounds like with the headers installed, check out the link below!
YouTube
Here come the pictures:
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OMG!!!! I read and read this prob 3 times and I’m a little confused and hoping you read this and are still around the forum to help me out and other members as well... so you have 2” BODYLIFT... and you went through all these problems... would a suspension lift have done the same or was it strictly because you lifted body you were experiencing this with the steering shaft.? Now if someone who has a suspension lift of about 2.5” were looking at these DT headers and had a 2003 T4R v8 would you recommend they get the 05-09 headers right off the bat due to the egr tube etc? Or they will
Be fine with the 03-04 headers?? And looking back... would you just remove the 2” BL OR ..?? Also how’s everything now.?? Also if anybody else can chime in it would
Be appreciated !!!
Thank you... I replied to that one and had one more question. Thanks so much.!
monkeymayng
New member
BUMP for update 
Hey Cpt!
Just wanted to see what you ended up going with for your cat-back exhaust option. And do you have another clip of what it sounds like now?
I just came across this thread, and I agree that that the straight pipe sounds awesome. But I also agree that it could become annoying - especially after long distances. I would love to hear an update though and see how things are progressing!
Thanks for putting this together and take care brutha!
Hey Cpt!
Just wanted to see what you ended up going with for your cat-back exhaust option. And do you have another clip of what it sounds like now?
I just came across this thread, and I agree that that the straight pipe sounds awesome. But I also agree that it could become annoying - especially after long distances. I would love to hear an update though and see how things are progressing!
Thanks for putting this together and take care brutha!
Who has had success installing the dt headers on 05-09 v8 and has a 1" body lift? Anything that was needing to be customized to make fit? In the middle of installing and want to try to limit any complications that may arise. Read through the thread and appears the steering shaft may be in the way? Solutions? Beers on me to anyone who points out issues and solutions before they come up...
Inv4drZm
Senior Member
Long tube or short tube headers?
My long tubes headers barely rubbed the steering shaft bolt, so I ground down the bolt until it no longer rubbed. I have a 1.5" body lift.
Long tube. So far I figured i haven't heard from my mechanic, so no news is good news.
Have a two inch body lift on my 04 v8. Ordered my Doug Thorley long tube headers from burtman industries and he said that this problem was only with the short tubes not the long tubes. But we will see.. Haven't gotten them installed yet. But definitely not smashing mine with a hammer if a problem comes up. I will do something to the steering shaft hopefully to avoid it
Cpt_Romania
New member
Hey hey,
It's been awhile. Alright so the 4runner is still running the same as before, no different sounds, feels, smells etc. It's running just as loud and strong as before and turns just as many heads
I'll get something together for another video/audio update soon.
So I have (2) magnaflow catalytic converters and that's it. Yup, after the cats it's straight piped 2.5" pipe into a hard right behind the passenger rear tire for wheeling purposes.
Thanks for the interest!
Cpt_Romania
New member
I hope you can figure something out, not sure what relocation you could possibly do but GL ��
Again, closing on 25k miles since the "header abuse" and the truck is running the same as day one. I don't have anything negative to say about smashing them with a hammer, I've done it, others have done it. I've yet to meet someone who HAS done it and had negative effects. Just my 2¢.
But for me - to continue running meaty 35s and and to fit them EASILY, I couldn't go any lower on my 2" BL. And I had to get the exhaust tick fixed, so in that dilemma, I chose to take the risk with the headers and from my experience, it's paying off.
I roll on 35s, sound like a Mustang and can set cruise control at 80 and not even struggle ��
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RivMan
Member
Here are some REAL dyno numbers showing the "Massive" power lost when you dent headers like that.
Exhaust Header Bash! Testing Power Loss From Dents - Engine Masters Ep. 4 - Dailymotion Video
The results surprised me.
-Rob
Exhaust Header Bash! Testing Power Loss From Dents - Engine Masters Ep. 4 - Dailymotion Video
The results surprised me.
-Rob
Cpt_Romania
New member
It surprised me too this should settle this thread, FACTS, no more lovely opinions
Case closed.
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