250ci long tube headers interference issues

[shelby987]

Hoping someone can help me with this, I need to know if anyone has any advice on how to run long tube headers around the crossmember for the transfercase/transmission on a 250 I6 4x4. Not sure if the cross member is in the same place for a 2wd or not, but right now my headers dump out right infront of the cross member, not sure if I should try to go above or below the cross member.....being as its a 4x4, I would prefer to go above(ground clearance), not sure how much heat the dana 20 transfer case can take.

Also, due to this issue, currently running open headers, this is a first, is it normal to have a regular loud pop every 3-4 seconds? I have just installed a new carb, but I don't think that would cause this.....out of timing...correct timing for a 250?

[shifty]

i had nothing but a bear of a time installing headers for my inliner w/3spd and 2wd. pictures are here:

http://satellitehead.com/gallery/thumbnails.php?album=8

My crossmember was at the bellhousing in front, just under the body seam at the base of the firewall on the cab.

[shelby987]

ah, this is where the problem differs though, my headers dump out directly in front of the cross member for the transfer case/trans. I either have to go above or below that to do anything, they don't sit below the cross member like yours.

It seems to be the nature of the beast with these inliners.....doing this all by yourself was definately a P.I.T.A! Don't even get me started with regard to hanging the intake and 4bbl carb.....you have to install both together, because clearances between my pb booster and carb body was on the order of 1/4"....and if you installed the intake then the carb, you couldn't get the body over the 4 studs.
Think I have a pic, here it is, this will the be the 3rd air cleaner I have had to buy to accomodate my pb on the I6

[shifty]

you could have gotten a smaller diameter PB booster. there are people out there with a double-pump or double-diaphragm 7" or 9" booster out there (whatever), looks like you have an 11" or something?

sorry i can't help more with your setup. i know exactly what you are dealing with and i know how frustrating it is. seems like the things you'd expect the most simple - like removing your gas tank and mounting one under your bed, installing headers that are "supposed" to fit or whatever it may be, a 2 hours job turns into a 2-day job ... or, in my case, it literally took me almost 2 weeks to get mine painted and installed with all linkage in place....only to run the engine for about 10 miles, then take em off and sell em to another board member for $50 less than what i paid for them shipped.

[shelby987]

lol, why would you do that?
When I bought the pb booster, I just purchased a stock 3/4t booster.....I didn't have any thoughts in my head about possible clearance issues with my new intake and carb......and aside from some scratched paint on the booster, I think I made it out ok.....sometimes you are dumb, sometimes you are lucky....but to be both is to be truely blessed!

ttt for anyone who thinks they have a solution to go around that cross member, I will post some pics tonight.

[zeeklu]

I have a 292 4WD and had the same issue. I had to make up a pipe to go up and over. I'll post a picture after I go out in the garage and take a picture. Chris

[zeeklu]

[shelby987]

anybody know what an exhaust shop might charge for that?
zeeklu, any problems with that much heat at the transfer case?

[shifty]

I'm guessing you could probably get something like that done for less than a C-note.

[zeeklu]

I don't think heat would be a problem because the stock exhaust goes through there anyway. Chris