Almost ready to install new headers and power steering gear box

[marklfarkl]

As luck would have it the first day of driving my new 72 Challenger resulted in the long tube headers getting bashed when I was exiting a steep driveway. :angry1:

Pulled out the headers and discovered these holes near the top! :icon_scratch:

Purchased this set of Dougs ceramic headers. They are not supposed to hang as low as the long tubes that were on there before and should also keep the temps down as well. :icon_smile:


While attempting to determine how bad the exhaust leak was, I also discovered that the power steering gear box was dribbling fluid as well. :crybaby2:
[video]https://youtu.be/AhESCKozhqE[/video]

Purchased this replacement steering gear box from Summit racing . Did consider going with the firm feel stage II, but at over $220 more than stock it's just outside my budget for now.


The headers require a mini starter. Purchased this one from Amazon. As you can see this mini starter is much smaller than the stock unit.

These headers also need a smaller oil filter as well. Went with a Fram PH16.

Used this video to learn what steps were involved with pulling the steering gear box.
[video]https://youtu.be/3M87tc9B4C0?list=PLE7HmOVryX_Hk691SdKNTLtjeJOvYT2e G[/video]



Discovered that a Torx T30 driver is the perfect size for punching out the steering coupler roll pin.

Steering coupler seal cover came loose when I pulled out the steering column.

Did some research on this and discovered this crimped connector comes out easy. It was a such a problem that a retaining clamp was developed and released per Technical Service Bulletin No. D69-19-4. Purchased the, "Mopar 2996935 Steering Coupler Retaining Clamp" on ebay for $20.

Now that I have the power steering gear pulled out installing the new headers should be a cakewalk right?! :eusa_shifty:

 

[Chryco Psycho]

good progress , I guess you do not want to know that you could have used a $20 mini starter off a truck from the wreckers & put the extra cash towards the Firm Feel steering box though

 

[mmissile]

That clamp takes some doing to get on.

 

[moparleo]

Did your headers come with install instructions ?

 

[marklfarkl]

good progress , I guess you do not want to know that you could have used a $20 mini starter off a truck from the wreckers & put the extra cash towards the Firm Feel steering box though

When researching mini starters I discovered that they are easily found at a pick and pull junk yard. Decided not to go that route as the amount of time required for me to do it was not worth the $43 in savings. I'm also a sucker for shiny brand new parts. :laughing7:

 

[marklfarkl]

Did your headers come with install instructions ?

Yeah, here they are for your viewing pleasure. :icon_smile:

 

[marklfarkl]

That clamp takes some doing to get on.

Yeah, it looks like it may be a pain alright...

 

[moparleo]

The question about the instructions was for your benefit, not mine. I thought that you were serious when you said" it should be a cake walk right ?" Sorry

 

[marklfarkl]

The question about the instructions was for your benefit, not mine. I thought that you were serious when you said" it should be a cake walk right ?" Sorry

Reading the directions is great :newbie: advise. I know many who do not. Sometimes that includes me! :icon_mrgreen: But not in this case.
The directions do not require the power steering gearbox to be removed. Have you ever installed long tube headers and a power steering box at the same time? Was there anything you encountered that was not in the instructions? Perhaps a gotcha or a shortcut? Any tips or advise would be greatly appreciated!

 

[moparlee]

As long as you are this far into the project, you might as clean and rebuild if necessary the steering coupler. You will probably need to pull the steering column to get the small pin out of the shaft.

 

[moparleo]

I installed TTI's in my Challenger. No problems, but I also have the Uni-steer Rack & pinion conversion.

 

[marklfarkl]

As long as you are this far into the project, you might as clean and rebuild if necessary the steering coupler. You will probably need to pull the steering column to get the small pin out of the shaft.

I cleaned it. All that is left to do is repack with grease.

 

[marklfarkl]

Apparently my motor mount nuts were welded in place.
:thatswck:


Got the bolts out after this discovery.

 

[DetMatt1]

Lol! That's not wack, it's the way Ma Mopar saw fit to do it and when you know that they're welded to begin with it makes for an easier job removing and installing them. Nice progress, hope the rest of it goes smoothly.

 

[moparleo]

Good thing you didn't use a quality tool.

 

[Chryco Psycho]

The nuts are always welded onto the mounts

 

[marklfarkl]

I'm learning a lot and having fun! Got the headers in.



The far left original header nut is not tightening up as the bolt keeps turning in place. Removed it from the head. The bolt threads are fine which means the threads inside the head must be stripped out. Looks like the most common repair is to use is a heli coil. Required drill size for tapping is 21/64. Hoping I can do this without needing to pull the headers out.

 

[marklfarkl]

Got the starter in today. Waiting for the heli and power steering gear to arrive in the mail. :sleepy2:

 

[marklfarkl]

The Heli coil and 21/64 dril bit arrived today. Drill bit went right through the header bolt hole and stopped at the heads. Gave it a few turns and pulled it out. Thread sealer on the end of the bit made a nice mark which along with the header stud helped me gauge the drill depth.




Drilled into the head up to the tape marker.



Carefully tapped the hole. Used a little lubricant oil aid in the tapping.



Screwed the heli coil in (forgot to take a photo), then added more thread sealer to the header stud screw back in and it fits nice and tight. :icon_thumright:

 

[marklfarkl]

Got a letter from Summit racing. The power steering box has been delayed over a week.:icon_sad:

If I'm going to wait I might as well get something waiting for. Canceled my order and plan to go with the firm feel stage III

So much for staying on budget.