FORD RAPTOR SUPERCREW 6.2L, 4WD

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1 THY-223Y-1-C LEGALITY NOTES These exhaust headers DO NOT comply with California Air Resource Board regulations and are NOT LEGAL for sale or use on pollution controlled vehicles in the state of California. These headers are intended for use on vehicles that are involved in closed course racing applications only. They will be referred to as RACE USE ONLY in any other location in this instruction sheet, or any marketing information. The installation of exhaust headers onto any vehicle must be performed in accordance with all governmental regulations that pertain to the particular vehicle receiving the headers.

2 PARTS INCLUDED Ref. Part Number Description Qty 1) Driver Side Header Assembly 1 2) Passenger Side Header Assembly 1 3) Main Y-pipe Assembly 1 4) Driver Side Connector Pipe Assembly 1 5) Passenger Side Connector Pipe Assembly 1 6) Band Clamp 3 7) M x30mm Hex Flange Head Bolt 2 8) /8-16x2.25 Hex Head Bolt 4 9) /8-16 Hex Nut 4 10) /8-16 Toplock Hex Nut 4 9) /8 Flat Washer 8 TOOLS REQUIRED Ref. Description 1) 3/8 Drive Ratchet and Extensions 2) 7/8 Box wrench or O2 Sensor Socket 3) 9/16 Box Wrench and Socket 4) 8mm, 10mm, 12mm, 14mm Sockets 5) 8mm, 10mm, 12mm, 14mm Wrenches Ref. Description 6) Metric Allen Wrench Set 7) WD40 or equivalent 8) Sawzall, hack saw, or equivalent 9) High strength thread locker 10) High temperature silicone sealant WARRANTY NOTES 1) The utmost care is taken at Doug Thorley Headers ( DTH ) to maintain the highest standards of quality. However, DTH cannot control the installation of the product. For this reason the warranty covers only the replacement of the components, it does not cover labor for the installation. 2) The use of any type of header wrapping immediately voids the warranty. Using any sort of wrapping material on the headers destroys the tubing s ability to dissipate heat, causing very rapid deterioration of the composition of the metal and the subsequent failure of the headers. 3) Any chrome plating applied to DTH header components is a high-nickel chrome finish applied to retard corrosion. This is a commercial quality heat chrome designed to protect the metal from the environment only. This finish is not show chrome and is not intended for the sake of appearance. This high-nickel chrome will turn colors and approach black as it cooks into the metal. The initial brilliance of the chrome finish is not covered under the warranty. Contamination of the surface by foreign substances may produce other color patterns. This can be prevented by routine cleaning. 4) Retain all paperwork pertaining to the purchase of your DTH product. Save your receipt! Your limited lifetime warranty is not valid without a receipt of your purchase.

3 INSTALLATION NOTES 1) It is important that you read the entire instruction sheet before beginning any installation. 2) Due to restricted room in the engine compartment your headers may come close to certain body and chassis components, this is normal for an installation of this type. However, a careful inspection must be completed to ensure that the distances and placement are reasonable and logical, especially with regard to electrical, fuel, and brake components. 3) Because of car-to-car variations, DTH strongly recommends that these headers be installed by an experienced installation shop that has a vehicle lift, fabrication and/or welding experience. NOTE: Installation of these headers is quite difficult, and will take a good amount of time. Please be sure that you are capable of performing all tasks required to complete the installation before beginning. 1) Disconnect both battery terminals. 2) Cut the factory y-pipe assembly between the passenger side catalytic convertor and the y-pipe collector. Doing this will ease removal of the factory y-pipe. (Fig. 1) 3) Disconnect and remove all four O2 sensors from the factory exhaust system. 4) Remove the four bolts securing the stock exhaust manifolds to the y-pipe inlets. 5) Loosen the band clamp nut on the driver side. 6) Remove the two bolts securing the y-pipe to the exhaust system inlet. 7) Remove the factory y-pipe sections from the truck. 8) Remove the bolts securing the driver side manifold heat shield, and remove the heat shield. 9) Remove the two bolts securing the passenger side heat shield. 10)On the passenger side, disconnect the wiring and remove the three starter mounting bolts. Remove the starter from the truck. 11) Find a suitable place on the passenger side to jack the engine up and lift just enough to support the engine.

4 12)Remove the three engine mount bolts (engine mount to engine block). 13)Loosen both large engine mount nuts (engine mount to frame). Remove the nut closest to the driver side, and leave the nut closest to the passenger side on with a few threads showing. (Fig. 2) 14)Lift the engine just enough to finish removing the passenger side manifold heat shield form the truck. 15)With the engine still lifted, remove all passenger side manifold nuts and remove the manifold from the truck. Retain all hardware and factory gasket. 16)Remove the engine oil dipstick. 17)Remove all driver side manifold nuts and remove the manifold from the truck. Retain all hardware and factory gasket. 18)Inspect both the factory gaskets and the cylinder heads. Clean all excess carbon deposits and/or dirt from the gaskets and cylinder heads. 19)Mark the orientation of the steering shaft to rack, and remove the pinch bolt. Move the steering shaft out of the way. 20)Carefully remove all of the top manifold studs from the driver side cylinder head. 21)Place the factory gasket onto the lower studs on the driver side cylinder head. Install the new Driver Side Header onto the lower studs. 22)Loosely secure the header to the cylinder head using one supplied M x30mm Hex Flange Head Bolt. This bolt will be installed on the top in the second position from the front. 23)Loosely secure all other header flange mounting points using the original studs and nuts. It is very important that you start all hardware prior to tightening anything. Do not fully tighten at this time. 24)Starting with the centermost hardware, tighten all driver side header flange hardware to factory specification.

5 25)Reattach the steering shaft to the rack. 26)Remove the third manifold mounting stud from the front (top) on the passenger side cylinder head. 27)Remove all three floorboard heat shield (large heat shield on passenger side) bolts and slide the heat shield back & out of the way. 28)Place the factory gasket onto the studs on the passenger side cylinder head. Install the new Passenger Side Header onto the studs. NOTE: It may take a few different engine positions to work the passenger side header up to the cylinder head, be patient. 29)Loosely secure the header to the cylinder head using the supplied M x30mm Hex Flange Head Bolt. This bolt will be installed on the top in the third position from the front. 30)Loosely secure all other header flange mounting points using the original studs and nuts. It is very important that you start all hardware prior to tightening anything. Do not fully tighten at this time. 31)Starting with the centermost hardware, tighten all passenger side header flange hardware to factory specification. 32)While the engine is still lifted, reinstall the engine oil dip stick. NOTE: Remember that it is routed behind the motor mount. 33)Reinstall the starter and all wiring connections to it. 34)Install the original front O2 sensors into the bungs provided on the headers. Reconnect the O2 sensors to the wiring harness. 35)Slide the floorboard heat shield back into position. If it comes into contact with the header you may need to bend the heat shield, or trim it slightly. 36)Secure the floorboard heat shield using the original bolts. 37)Lower the engine down into the original position and fully tighten all engine mounting hardware to factory specification.

6 38)The new Y-pipe Assembly requires you to cut the factory flange from the exhaust system inlet in order to accommodate the new y-pipe. Cut the exhaust system 1.75 from the weld on the back side of the flange. (Fig. 3) 39)Deburr and clean the cut end of the exhaust system. 40)Place one supplied Band Clamp over the notched portion of the Y-pipe Assembly. Apply some high temperature silicone sealant to the exhaust system inlet and slide the y-pipe assembly into position over the exhaust system inlet. Do not tighten clamp at this time. NOTE: In order to accommodate installation of the new y-pipe components, you may need to take the exhaust system completely out of the hangers. 41)Place one supplied Band Clamp over the notched passenger side inlet of the y-pipe assembly. Apply some high temperature silicone sealant to the outlet of the Passenger Side Connector Pipe and slide it into the passenger side y-pipe inlet. 42)Position the passenger side connector pipe over the passenger side header outlet. Using the supplied 3/8-16x2.25 Hex Head Bolts (2), 3/8-16 Hex Nuts (2), and 3/8 Flat Washers (4), loosely secure the connector pipe to the header outlet. Do not fully tighten at this time. 43)Place one supplied Band Clamp over the notched outlet of the Driver Side Connector Pipe. Apply some high temperature silicone sealant to the driver side inlet of the y-pipe assembly and slide the driver side connector pipe into place. 44)Position the driver side connector pipe over the driver side header outlet. Using the supplied 3/8-16x2.25 Hex Head Bolts (2), 3/8-16 Hex Nuts (2), and 3/8 Flat Washers (4), loosely secure the connector pipe to the header outlet. Do not fully tighten at this time. 45)Once you are satisfied with the positioning of all y-pipe components and the exhaust system, you may fully tighten all band clamps and header outlet hardware. 46)Thread one 3/8-16 Toplock Hex Nut onto the exposed threads of each 3/8-16x2.25 hex head bolt installed in Step #42 & 44. Using a wrench to hold the hex nuts in place while securing the toplock nuts to the hex nuts with a second wrench. 47)Install the original rear O2 sensors into the bungs provided on the y-pipe assembly. Reconnect the O2 sensors to the wiring harness. NOTE: You may need to use some wire ties to secure any O2 wiring away from exhaust components.

7 48)Inspect engine compartment and components around the headers for clearance issues. Wipe excess oil, grease and finger prints off of the headers with acetone or equivalent. 49)Inspect the entire header installation for any loose hardware that may have been missed. 50)Reconnect the battery. 51)Start the engine and check for any exhaust leaks. 52)It will be necessary to re-torque nuts and bolts once the engine has reached operating temperature, and has cooled back down. CATALYTIC BREAK-IN PROCEDURE New catalytic convertors require a break-in period in order to work properly 1) Start the engine and allow it to idle for 5 minutes without touching the accelerator. 2) After 5 minutes, raise the RPM to 2500 for another 2 minutes. 3) Allow the engine to cool. Fig. 1

8 Fig. 2 Fig. 3

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