Originally Posted by Electronut
Jeff - Let me know how you tackled the job. You have a lift? Air tools needed or you did with standard ratchet/socket sets?
Mine just like everyone elses Im sure is rusted to crap. How difficult was the crack those bolts off? Did you do from top or bottom? I was checking out and appears for passenger side anyway you can get to bolts from the top. Unboting the exhaust pipe from the headers I imagine could be a PITA.
Give some pointers on how you took on the project if you can. Maybe I will just attempt this on my own.
Here what i did and used....
Only useing hand tools to complete the job. No lift is needed but will make life easier.
As you had stated, the bolts are rusted to hell. So on a cool engine spray every bolt and nut on the manifolds to the y pipe in wd 40 or pb blaster. Let it sit for a little while. (30 min should be good) start with the y pipe bolts as they will be the most difficult ones and you will likely snap em. Once you get the y pipe bolts out, move to the nuts holding the heat shields on. Once they are off you will not be needing them again. Wont fit over the headers. Coming from up top, start working the top manifold bolts out, it will be very cramped. Especially on the drivers side. Then work the bottom ones from underneath.
On the passenger side, once its off it should drop right out but if it dont. Feed it along the frame rail towards the radiator. There should only be the heater core lines to slightly move out the way. The right side must go in from the same way. Slid along the frame rail to the head.
Drivers side. The starter must come out. And the header can be dropped straight out the bottom. New one goes in the same way. This is where you will need to check clearence on the steering shaft bracket. Mark and indent if needed. If not install the bolts holding it to the head with the gasket. If it helps place the gasket on the header and use a bolt to help align it on the head.
I recommend replaceing the grade 5 y pipe bolts for grade 8 ones. Ive had the grade 5 ones come out going down the road. Problem is solved with grade 8 ones. Also recommend having a buddy help as the second pair of hands will be usefull in lining everything back up.
Did mine on the ground in 4.5 hrs witht a buddy