Gibson GP312S-C User manual

GP312S-C
CERAMIC HEADER
04-05 DODGE RAM STR-10 1500 PICKUP
8.3L , 10CYL 2WD AUTOMATIC
GIBSON HEADERS ARE 50 STATE SMOG LEGAL
/
2Thank you very much for purchasing our Gibson header
for your vehicle.
If you need further assistance, please do not hesitate
to call our Technical Department at [phone]
Monday through Friday
8:00 a.m. to 5:00 p.m. PST.
1270 WEBB CIRCLE CORONA, CA 92879
0905

WHEN THESE INSTRUCTIONS ARE FOLLOWED PRECISELY, YOU WILL FIND
THE INSTALLATION OF YOUR EXHAUST SYSTEM TO BE RELITIVELY
SIMPLE. WE CANNOT OVER EMPHASIZE THE IMPORTANCE OF ADHERING
STRICTLY TO THIS PROVEN APPROACH, AS IT WILL VIRTUALLY ELIMINATE
ANY DIFFICULTIES, WHICH YOU MIGHT OTHERWISE ENCOUNTER.
NOTE: INSTALLATION OF HEADERS ON VEHICLES WITH CATALYTIC
CONVERTERS AND/OR OTHER EMISSION CONTROL EQUIPMENT MUST BE
ACCOMPLISHED IN ACCORDANCE WITH ALL GOVERNMENT REGULATIONS
PERTAINING TO SUCH EMISSIONS STANDARDS.
WARNING: MAKE CERTAIN YOU HAVE ENOUGH CLEARANCE AROUND
BRAKE, FUEL, AND ELECTRICAL LINES, ETC. IN SOME CASES, IT MAY BE
NECESSARY TO RELOCATE ITEMS WHICH MIGHT BE ADVERSELY AFFECTED
BY EXHAUST HEAT.
WARNING: INSTALLATION OF ANY TYPE OF "WRAPPING" MATERIAL
ONTO THE HEADERS WILL DESTROY THE HEAT DISSIPATION PROPERTIES
OF THE TUBING, CAUSING PREMATURE DETERIORATION OF THE METAL
AND SUBSEQUENT FAILURE. USE OF ANY "WRAPPING" MATERIAL WILL
VOID THE WARRANTY.

SUGGGESTED TOOLS
13mm, 12mm” WRENCHES (VARIOUS LENGTHS)
12mm, 13mm” SOCKETS (SHALLOW AND DEEP)
9/16” WRENCHES (VARIOUS LENGTHS)
9/16” SOCKETS (SHALLOW AND DEEP)
5/8” SPARK PLUG SOCKET
15MM DEEP SOCKET
15MM BOX END WRENCH
3”, 6”, AND 12” EXTENSIONS FOR SOCKETS
HIGH TEMP SILICONE (ULTRA COPPER BY PERMATEX)
GOOD RUST PENETRANT

INSTALLATION INSTRUCTIONS
STAINLESS SHORTY HEADERS
NOTE: Installation of these headers requires an adequate workspace,
general mechanic's tools general mechanical "know how”. You should
carefully read these instructions before attempting to install these
headers. This part is legal on Emission Controlled Vehicles.
1.Place vehicle in a location where the floor is solid and flat, with
adequate lighting. Do not attempt to work on a hot engine. Heat causes metal
to expand and makes removal of fasteners difficult. Disconnect the battery
cables from the battery. Raise the front of the vehicle to obtain adequate
access to the bottom exhaust manifold flanges. Use large-base jack stands to
support the vehicle. Do not rely on the jack! Block the tires to prevent
the vehicle from rolling off the jack stands. Use safety glasses.
2.Spray WD-40 on all accessible fasteners and fittings before attempting to
remove them.
3.From underneath the vehicle loosen the bolts that hold up the y-pipe
assembly on both driverside and passengerside.
4.Starting at the top, to remove the driver's side manifold first remove the
driverside heat shield on the manifold. Then remove the manifold hardware
through the top of the engine compartment.
5.Using a scraper, remove all carbon deposits and high
spots from head surface. Apply a high temperature gasket sealer to exhaust pipe
flare in order to avoid problems due to lack of space later in the
installation.
6.Recommended to remove steering shaft for easier installation of header.
Note: Mark alignment of shaft. Install driver’s side header using new head
gasket + bolts. Use a high temp gasket sealer (O2 sensor safe) on head
gasket. Install header through the top of engine compartment. You might have
to move hoses, wires and steering shaft out of the way for easier
installation. Starting from the center bolts in and working your way out.
Torque all fasteners to 30 to 35 pounds. Then, after installation of header
is done, wrap steering shaft with supplied heat-wrap and wire strips on
vehicle. As shown in the picture.

7. Starting at the top, to remove the passengerside manifold first remove
the passengerside heat shield on the manifold. Then remove the manifold
hardware through the top of the engine compartment.
8.Using a scraper, remove all carbon deposits on head surface. At this time
apply a high temperature sealer (O2 sensor safe) to exhaust pipe flare in
order to avoid problems due to lack of space later on in the installation.
9. Install passengerside header using new head gasket + bolts. Use a high
temp gasket sealer (O2 sensor safe) on head gasket. For easier installation
pry the inner fender wheel away from header. Towards the tire for
installation of header and hardware. NOTE: Last top bolt use 3/8” or 1/4”
extension & socket to install hardware for easier installation. Torque all
fasteners 30 to 35 pounds. Tighten all bolts starting from the center and
working your way out.
10. Pull heater hose away from header and clamp using zip ties provided to
keep from resting on header.
11.Reconnect the y-pipe assembly to the header using the hardware provided
torqueing to 50 fts.
12.Check to make sure there is adequate clearance on battery cables, wire
looms, brake lines, etc.
13.Re-connect the battery cables.
14.Recheck and tighten everything!
15.Start the engine and let it warm up. Check for leaks. Shut engine off and
let it cool down. Check to make sure all fasteners are tight.
YOU MUST RE-TORQUE ALL HEADER BOLTS AFTER 100 MILES AND THEN PERIODICALLY
CHECK.
NOTE: IT IS NOT UNUSUAL WHEN INSTALLING HEADERS TO GET A BURNING SMELL. THIS
IS NORMAL AND IT WILL GO AWAY!

PART LIST:
Part # Qty. Description Part # Qty. Description
GP312D 1 DRIVERSIDE HEADER 9535 6 FLAT WASHER 3/8” X
3/4”
GP312P 1 PASSENGERSIDE HEADER 9033 6 3/8” LOCK WASHER
9251 2 PASENGERSIDE/DRIVERSIDE GASKET 5057 6 3/8” X 16” NUT
951 20 5/16” X 1” HEADER BOLTS 345 6 3/8” X 2 1/2” BOLTS
225 20 5/16” STAR WASHERS ZIP 4 ZIP TIES
IT IS CRITICAL THAT ALL BOLTS BE RE-TIGHTENED HOT AFTER ABOUT 20 MINUTES OF
OPERATION TO PREVENT GASKET FAILURE.
NOTE: HEADERS ARE NOT MEANT TO SERVE AS “EXHAUST SYSTEM SUPPORT HANGERS”.
ADDITIONAL HANGERS MAY NEED TO BE ADDED AT THE TIME OF THE INSTALLATION OF THE
HEADERS SO THAT THE EXHAUST SYSTEM SUPPORTS ITSELF WHEN THE COLLECTOR BOKTS

ARE REMOVED. HEADERS THAT HAVE “SAGGED” DUE TO THE LACK OF SUFFICIENT EXHAUST
SYSTEM SUPPORT WILL NOT BE REPLACED UNDER WARRANTY.
NOTE: HEADER BOLTS SHOULD BE INSPECTED FOR TIGHTNESS FROM TIME TO TIME TO
ENSURE OPTIMUM GASKET LIFE. THE BOLTS WILL STRETCH SOME AT FIRST DUE TO THE
EXHAUST HEAT; SO, THEY’LL LOOSEN WITHOUT TURNING UNTIL THEY “TAKE A SET”. (BOLTS
HARD ENOUGH NOT TO STRETCH WOULD BREAK!) WE’VE EXPERIMENTED WITH THE VARIOUS
“LOCKING DEVICES” ON THE MARKET, WHICH PREVENT BOLTS FROM TURNING. THEY DON’T
WORK ON HEADER BOLTS, AND THEY GREATLY COMPLICATE THE PROCESS OF RE-TIGHTENING
THE BOLTS WHEN IT’S NECESSARY.
WHAT DOES WORK IS THIS:
GO OVER THE BOLTS AGAIN AFTER THE FIRST DAY OF DRIVING (OR ABOUT 100 MILES-
WHICHEVER COMES FIRST) THEN AFTER THE FIRST WEEK, AFTER THE FIRST MONTH, AND
THEN EVERY 6 MONTHS. OUR EXCLUSIVE GASKETS ARE SPECIALLY MADE SO THAT THE
CYLINDER HEAD SHOULD BEGIN TO MELT BEFORE THE GASKETS CAN BURN UP. ABOUT THE
ONLY WAY TO KILL THE GASKETS IS TO LET THE HEADERS GET LOOSE AND THEN KEEP
DRIVING WITH A LEAK.
DUE TO VARYING CONDITIONS BETWEEN GEOGRAPHICAL LOCATIONS AND USAGE, WE
STRONGLY RECOMMEND HAVING THE ENGINE RE-TUNE AT A REPUTABLE TUNE-UP SHOP AFTER
THE INSTALLATION OF THE HEADERS. DOING SO WILL ENSURE THAT YOU GET THE
MAXIMUM BENEFIT FROM THE INSTALLATION OF THE HEADERS.
GIBSON PERFORMANCE STRIVES TO DELIVER THE HIGHEST QUALITY MATERIALS,
WORKMANSHIP, AND SERVICE. PLEASE SO NOT HESITATE TO CALL OUR TECHNICAL LINE IF
YOU HAVE A QUESTION OR EXPERIENCE A PROBLEM.