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How to Install BBK Full-Length Headers w/ Y-Pipe - Catted on your 2007-2011 3.8L Jeep Wrangler JK

Installation Time

4 hours

Tools Required
  • Jack to support transmission
  • Zip Ties
Extreme Terrain
Shop Parts in this Guide

Hardware Included

• KIT007
   o HDW152 Stud, M12-1.75x65MM (4pcs)
   o HDW040 Hex Nut, M12-1.75 (4pcs)
   o HDW021 Lock Washer ½” (4pcs)
   o HDW023 Flat Washer ½” (4pcs)

• CHD343 12” Oxygen Sensor Extension (2pcs)
• CHD343-1 24” Oxygen Sensor Extension (1pc)
• 00105 Gasket Kit (1pc)

Difficulty: 3 out of 5


Follow these instructions carefully to ensure correct fitment and operation.

STEP 1

• Disconnect the negative battery terminal. Lift the vehicle.

STEP 2


• Loosen the clamp at the factory Y-Pipe. Remove the rubber grommets holding the exhaust. Loosen the connection at the head pipe and muffler, then remove the head pipe and let the muffler hang out of the way. NOTE!!! Be sure to use lubricant to aid the removal of the rubber grommets and muffler.

STEP 3

• Before removing the factory Y-Pipe you must support the transmission or transfer case, and then remove the Cross Member by removing the 2 bolts on each side of the cross member and any hardware that connects the transmission to the cross member. On 4x4 applications you will also need to loosen the drive shaft at the front differential and let the driveshaft hang at the transfer case. Remove the Y-Pipe from the vehicle.

STEP 4

• Disconnect the oxygen sensors.

STEP 5

• Remove the driver side and passenger side heat shields and exhaust manifolds. Then remove the oxygen sensors.

STEP 6

• Be sure the heads are cleaned off from any debris or gasket material. Install the BBK Full Length headers using the supplied gaskets. NOTE!!! Be sure to re-install the drive shaft on 4x4 applications.

STEP 7


NOTE!!! The photo above shows the Y-Pipe as one piece. The Y-Pipe comes in 2 pieces and uses a supplied coupler. Install the YPipe and only snug the hardware at the collectors and coupler. Re-install the cross member. Be sure to check the clearances around the Y-Pipe. Then tighten all the connections starting with the coupler, ensuring that both tubes are straight and aligned properly. Then tighten the collectors.

• Re-install the factory head pipe and muffler, and then tighten all connections.

STEP 8

• Transfer the oxygen sensors from the stock manifolds over to the BBK Full Length headers. 

STEP 9


• Using the oxygen sensor extensions reconnect all of the oxygen sensors. NOTE!!! The longer oxygen sensor extension is used for the YPipe.

• Zip tie the Y-Pipe oxygen sensor extension away from the exhaust along the cross member

STEP 10

• Re-connect the negative battery terminal. Check all hardware after 100 miles of driving.