mcdanjw

I am trying to install some DC Sport headers, Model HHC5528.

I cannot get the rear manifold to fit onto the studs because the left side of it hits a metal bracket that looks to connect the transmission and engine. I don't see an easy way to loosen that bracket. I guess I could undo those to big bolts in the picture below, but I'm not sure what that would do.

I don't think moving the engine slightly will help since this bracket is attached to the motor. It's the big silver bracket on the left side of this picture. It's just barely in the way, and if the manifold was all the way on, it wouldn't be. It's just getting it over the studs where it hits it.

Has anyone experienced this problem? Any suggestions?

Rajca

iTrader: (8)

u need to loosen the rear motor mount bracket. had to do it on the old 2 bolt flange dc headers when i put them on. not sure if the newer design has the same problem

mcdanjw

So did you undo those two grey bolts in the picture? I'm wondering if the motor is going to shift if I do that and then I won't be able to line them back up easily.

Rajca

iTrader: (8)

i believe it was 3 bolts. it was 2 years ago so dont really remember. but a piece of wood on a jack and then just support the engine with the jack. dont lift it or anything

Nicks01CL-S

ok theres two options on this, i had the same problem.
1 u can put a jack under ur motor to hold it from falling or lift up from uptop, while u take that motor mount loose
2 (what i did) because i was lazy and love power tools i took a right angle grinder to the mount, yes in the car. made sure not to take too much off or hit anything. them it slid right in and no problems.

your choice. or theres a 3rd redneck option. beat the header tube in until it fits..lol just kidding.
just take the time to loosen the motor and it will be 100X easier

phee

iTrader: (5)

my xs headers fit without any of that crap :/ sorry u gotta go through that

RoccoRock

iTrader: (1)

I'm not sure about DC headers, but I do know that there are two different variations of the headers. One set is designed for the 6 speeds, and the other is for the automatics. The six speed ones look identical in regard to the front header and rear header. The autos on the other hand have the rear one with a slight bend in one of the header tubes to clearance that mount (a mount the six speeders don't have). So it sounds like you have the ones made for the six speed and from what your sig says, you have an auto. I don't know if you can even make them fit the automatics. If you could post pictures of the headers you actually have then I could determine which set you've got.

Rocco

RoccoRock

iTrader: (1)

^^^^Since I can't edit that last post forget what I said.... I've got it backwards. Sorry about that.

mcdanjw

Okay. Problem solved. It was going to be a major pain in the butt to move that motor mount bracket so I decided to mess around with trying to get it to fit.

I called DC Sports and they were awesome. The rep on the phone assured me that the model I have should fit with no modifications. They offered to help me any way they could. I was quite impressed. I'll definitely buy DC Sports products again.

So I got back under the car and messed trying to fit it on there more. And suddenly.... ON IT WENT. The trick was putting the right side on first and lowering the left. It BARELY fit, but it did, without any pressure.

INSTALLER ERROR!

Thanks everyone for your input!

phee

iTrader: (5)

better hope your mounts are perfect or it will hit the bracket and crack

mcdanjw

It clears the bracket easily once it's slid all the way against the motor.

I'm actually quite impressed with the quality of these headers. Everything lined up nicely. The collector pipes fit perfectly through the middle of the openings in the bottom of the engine compartment.

Very well engineered and manufactured.

In the computer world, I'd call my problem PEBKAC. It wasn't the header design at all.

Nicks01CL-S

wait how did u get them on without grinding or loosing the motor mount? i dicked with mine for an hour until i said f*ck it and got the grinder out.... oh well glad u like them

mcdanjw

I tried for about 30 minutes.

I had my friend try for about 10 minutes.

I even had my freakin' wife for 15 minutes.

Finally I called a friend who works as a mechanic in a peformance shop. He came over and slid it on in 5 minutes.

Not exactly sure what he did, other than his description which was "put it on the right side first and then it just slid right on to the left".

Though I was so glad he got it on, it made me wanna kill him.

Excelerate

iTrader: (1)

I'm glad to hear that DC's customer service was on point. They have been making some huge strides. In fact many of their headers are going to be made out of stainless steel with a ceramic coating so good things are coming from DC.

gnuts

iTrader: (1)

any chance they'll make them for the 6speeds in the future?

C-STYL

You said it before I could. Someone should make a pole to show how many 6speeders would be interested in DC headers that would fit our cars. Then make DC aware of the market opportunity.

6sp_03

yeah im in need of 6speed headers! any ideas?? affordable ones 400.00 or under

CL-S progression 01

iTrader: (2)

when u buy headers for our cars it says 2-3 hours for a professional.

Now i'm no pro that's for sure. All of my bolts were easily removable (i cracked them the day before so i knew what i was up against). Then right before i started i smashed my right hand on the ground while jacking up the car the bar slipped out cause I wasn't looking and was in a rush and then all my weight landed on my last 2 lil fingers.. so while ICING THAT I proceeded to remove the old headers.

From smashing my finger to starting up the car and checking for leaks. took 5 mins shy of 2 hours. I shit u not.

so my advise is... make sure the bolts come off... read a thread or 2 from someone who has successfully completed the header install and ur install will go even smoother than mine lol. no ice required

i told some other people how long it took me and some didn't even believe be. so believe what u like. I'm just trying to make the next guy's life easier.

P.S

the only weird/hard part was the rear header... to get it in there I went UNDER the car and slipped in there upside down (the only way it would fit) then once it's behind the motor... above the cross beam or w/e it's called then u 180 it and sit it on the heads.

^^ that was the only part I stumbled on for a min or 2

and no i didn't have nor use a tq wrench, and no i had no leaks

and re-use your header gaskets (header to head gaskets)

aep4749

Put me on that list for 6 speed headers

Nersh7

I would buy a second set of headers if DC made them for the 6-speeds.
I just put mine on this weekend, and having never done anything similar to this before it sadly took me around 7 hours lol and I have a leak somewhere