Author Topic: Smashed my long tubes on a steep driveway  (Read 8790 times)

Offline marcus

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Smashed my long tubes on a steep driveway
« on: August 08, 2015 - 01:53:45 AM »
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. 


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


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.  :bigsmile:


While attempting to determine how bad the exhaust leak was, I also discovered that the power steering gear box was dribbling fluid as well.  :22yikes:


Purchased this replacement steering gear box from Summit racing then changed my mind and went for the firm feel stage III.


The headers require a mini starter. Purchased this one from Amazon. Decided not to go with the $20 Dodge truck junk yard gear box as I'm a sucker for shiny new parts.  :) 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.




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.



Have the power steering gear pulled out and now ready to install the new headers  :2thumbs:
« Last Edit: August 08, 2015 - 06:57:03 PM by marcus »




Offline Katfish

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Re: Smashed my long tubes on a curb
« Reply #1 on: August 08, 2015 - 07:24:33 AM »
Good info, interested to hear how it comes together.
I bought 1 of those coupler clamps too, gave up trying to get it on, definitely not a easy slip- on deal.

Offline djw383

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Re: Smashed my long tubes on a curb
« Reply #2 on: August 08, 2015 - 08:27:21 AM »
I used this improved seal from steerandgear.com, item 2111, no more oozing of grease http://static.wixstatic.com/media/6dd5bf_0d15f54992194dcba33ca1c6917c484f.jpg_srz_p_492_417_75_22_0.50_1.20_0.00_jpg_srz

Offline marcus

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Re: Smashed my long tubes on a curb
« Reply #3 on: August 08, 2015 - 12:56:34 PM »
I used this improved seal from steerandgear.com, item 2111, no more oozing of grease http://static.wixstatic.com/media/6dd5bf_0d15f54992194dcba33ca1c6917c484f.jpg_srz_p_492_417_75_22_0.50_1.20_0.00_jpg_srz


Looks like that is much easier to put on!  If I have the same issue getting mine on as Katfish I may just get one.

Offline marcus

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Re: Smashed my long tubes on a curb
« Reply #4 on: August 08, 2015 - 01:07:02 PM »
Got the new headers in


The far left original header nut is not tightening up as the bolt keeps turning in place. Removed the bolt and stud from the head. Both bolt and stud threads are fine which means the threads inside the head are stripped out.  :swear:

Going to repair it using a heli coil. Required drill size for tapping is 21/64.

Offline jimynick

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Re: Smashed my long tubes on a steep driveway
« Reply #5 on: August 08, 2015 - 01:32:39 PM »
I believe that bolt may be a "wet" bolt and if it is, you may want to use a heat resistant sealer on the outside of the heli-coil as the heat and pressure can push fluid through it's threads. This subject has been mentioned before and you may find some threads here about it. I'd also use a stud rather than a bolt to take it easy on the casting/thread repair, but that's just my  :2cents:

Offline Chryco Psycho

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Re: Smashed my long tubes on a steep driveway
« Reply #6 on: August 08, 2015 - 05:07:28 PM »
See if you can get a timesert instead , a helicoil will be very hard to seal up as there is water behind that hole

Challenger - You`ll wish You Hadn`t

Offline marcus

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Re: Smashed my long tubes on a steep driveway
« Reply #7 on: August 08, 2015 - 06:00:07 PM »
Thanks for all the good advise. I have a heli coil so went with that. 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 lots more thread sealer to the header stud screw back in and it fits nice and tight.  Hopefully I got enough thread sealer in there to prevent leaking!

Offline Chryco Psycho

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Re: Smashed my long tubes on a steep driveway
« Reply #8 on: August 08, 2015 - 06:08:15 PM »
 :2thumbs:

Challenger - You`ll wish You Hadn`t

Offline anlauto

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Re: Smashed my long tubes on a steep driveway
« Reply #9 on: August 08, 2015 - 08:26:13 PM »
How come when I read the title of this thread I think of this picture ? :dunno:
I've taught you everything you know.....but I haven't taught you everything I know !
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Offline dodj

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Re: Smashed my long tubes on a steep driveway
« Reply #10 on: August 09, 2015 - 10:12:06 AM »
Excellent post marcus!!
I always appreciate the effort of people including lots of pics with their work.
It always helps others the board.
 :2thumbs: :2thumbs:

And Alan,  i don't think there is a good family friendly way to answer your question.   :bigsmile:
Scott
1973 Challenger  440 4 spd 
2007.5 3500 6.7 Cummins Diesel, Anarchy tuned.
Good friends don't let friends do stupid things. ........alone.

Offline marcus

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Re: Smashed my long tubes on a steep driveway
« Reply #11 on: August 09, 2015 - 01:53:31 PM »
Thanks for the feedback. As a newbie I try to help other newbies so they don't make the same mistakes I do.

Case in point -


Apparently, I am going to have to remove the drivers side header that I just installed  in order to get the new steering box in. 


This is what happens when you try to remove a nut that is welded on -

Motor mount nuts are welded in place. Take a close look to ensure you trying to remove the bolt and not the welded on nut  :newbie:

Offline jimynick

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Re: Smashed my long tubes on a steep driveway
« Reply #12 on: August 09, 2015 - 10:59:58 PM »
Hopefully you didn't use TOO much of your penetrant on that nut! LOL You must have been grunting when you did that- or you've got a 2ft Johnson bar!  :cheers:

Offline marcus

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Re: Smashed my long tubes on a steep driveway
« Reply #13 on: August 10, 2015 - 12:05:56 AM »
 Your right, the coupler put up with my air impact wrench then game over after I switched to the breaker bar.  :eek4:

Offline marcus

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Re: Smashed my long tubes on a steep driveway
« Reply #14 on: August 10, 2015 - 12:09:16 AM »
Looks like I'm going to have to wait for my firm feel stage III to be built. Not much left to do till then...