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How to Install BBK Chrome Shorty Headers on your F-150

Installation Time

1 days

Tools Required
  • 8,10,13,15mm wrenches
  • 1 1/16” wrench
  • 13,15mm sockets
  • 3/8 ratchet
  • various length extensions

Due to various EGR connection points throughout the application years, steel
caps have been provided for the front EGR ports if not used on your vehicle.

STEP 1: Disconnect negative battery cable.
STEP 2: Remove the air inlet tube at the throttle body and release clamps on air box to remove the air inlet tube and Mass Air Housing.
STEP 3: Remove the spark plug wires.
STEP 4: Raise vehicle and support on sturdy jackstands or place on vehicle lift.
STEP 5: Remove the nuts at the collectors for the mipipe and drop the midpipe down and back, out of the way. Fig. 1 and 2
STEP 6: Undo the EGR connection on the passenger side exhaust manifold. 1 1/16” wrench.
STEP 7: On driver side, remove dipstick and tube. Bend the front brake line slightly forward and you’ll have enough room to remove tube. Fig. 3
STEP 8: Remove nuts and studs and stock manifolds from both sides. The manifolds will come out from the top. Passenger side installs from the top and driver side from below. Fig. 4 and 5
STEP 9: Clean head surface and install the new gaskets and BBK headers with the supplied hardware.
STEP 10: Install the provided steel caps on front EGR ports if not used. If used, connect the tubes. Fig. 6
STEP 11: Reconnect the EGR tube on the passenger header. Reinstall dipstick and tube on driver side.
STEP 12: Reconnect spark plug wires.
STEP 13: Reinstall air inlet tube and Mass Air Housing. Reconnect clamps and tighten clamp at throttle body.
STEP 14: Install the supplied studs into the BBK collectors and connect the midpipe to the headers using the supplied nuts and washers.
STEP 15: Reconnect the negative battery cable.
STEP 16: Start engine and check for any leaks.
STEP 17: Header bolts should be rechecked after 500 miles or so.





BBK Performance’s #4008, #40080 Tuned Shorty Headers


Kit includes headers, gaskets, (2) EGR caps,
(12) header flange bolts, (4) collector studs,
(4) flat washers, (4) lock washers, (4) nuts.