Durango 5.9 Shorty Headers: Getting the Old Manifold Studs Out
On a first-gen Durango, the headers are the easy part. The old exhaust manifold studs are what can ruin your weekend.
The Short Answer (TL;DR)
Owners on this DodgeForum thread say you'll probably snap at least one manifold stud when you pull the stock manifolds off a 1999 Durango 5.9. Their fix is patience. Soak every stud and bolt in a real penetrating oil, again and again, for days if you can. Use a good 12-point or 6-point socket, work each bolt back and forth, and leave yourself a full weekend.
What the thread is about
CharlesG had a 1999 Durango with the 5.9 and 140,000 miles. It spent its early life in Utah before moving to Southern California. He wanted to swap the cast manifolds for shorty headers and was worried about snapping studs in the heads. The replies stick to that one job: getting the old manifold hardware out in one piece.
What you need
- Two or three cans of penetrating oil. The thread names PB Blaster, PB Rust Penetrator, and Liquid Wrench.
- A good 12-point socket. One reply says a 6-point instead. The thread never gives a socket size.
- A full weekend in case a stud breaks
Step by Step: Getting the Old Manifolds Off
Soak everything first
Before you turn a single bolt, drown every stud and bolt in penetrating oil. Let it sit 5 to 10 minutes and spray again. One reply says to repeat that about ten times, or until you feel good about trying them. CharlesG started oiling his bolts every day while he waited for the headers to show up.
Don't count on WD-40
Two replies say regular WD-40 is a cleaner, not a penetrating oil, so it won't do this job. One poster points out that WD-40 also sells a separate penetrant in its Specialist line. Either way, use something actually made to break rust loose.
Break them loose slowly
Use a socket that grips the whole flat of the bolt, not one that rounds the corners. On a stubborn bolt, loosen it a turn, then tighten it back a bit, and keep working it back and forth. Don't just lean on it. Even if you do everything right, the thread says you'll probably still snap one, so plan your time around that.
Leaks are a sign the studs are going
One owner had a big exhaust leak where the pipe meets the driver-side manifold. One stud there had rusted down to about half its normal thickness. He hadn't tried to tighten it because he was afraid it would snap. If you have the same leak, put headers and new hardware on the list instead of cranking on that stud.
The thread stops before the headers go on. It doesn't list gasket types, torque specs, bolt sizes, or how to pull out a broken stud. Follow your header maker's instructions and a service manual for those.
The headers we sell for this truck
We sell stainless steel headers for the 1994-2003 Durango with the 5.2L or 5.9L V8. Check your year and engine before you order.
Shop Durango 5.2/5.9 stainless headers
Frequently Asked Questions
Will I break a manifold stud?
The thread says probably at least one, even if you soak them well. Soaking them for days and working each one back and forth makes it less likely.
Is WD-40 enough to loosen them?
Not regular WD-40, according to the replies. Use a penetrating oil such as PB Blaster or Liquid Wrench.
Source: DodgeForum first-gen Durango shorty headers thread. The original discussion is on that thread.
