I am new to these forums, so I apologize if anything here is not posted correctly or in the wrong section etc.

I wanted to start a placeholder thread for the questions I have as well as documentation of a header install on my 04' ralliart. Install will hopefully be this weekend. But before all that, a few general questions.

1) I was reading that evo 8 shifters fit the ralliart? Does this shifter work? I think this is the same one that otter has?? When I talked to lancershop.com they seemed to confuse the matter for me. Or maybe I have the wrong shifter???

http://www.lancershop.com/customer/p...cat=114&page=1

"Rob: How can I help you today?
you: was wondering if
you: http://www.lancershop.com/customer/p...cat=114&page=1
you: fits a 2004 lancer ralliart
Rob: no just evo 8 and 9 (5speed)
Rob: what year is your car?
you: 2004 like I said above
Rob: is it an evo 8
you: pretty sure the evo 8 and lancer shifters are the same...
you: "fits a 2004 lancer ralliart" << did you miss this line?
Rob: I am sorry one moment please
Rob: We wouldnt recommend doing that.
you: so does it fit?
you: or not?
Rob: no it does not."

2) Lancershop.com suggests 2pc & 8pc stiff shifter bushings. I'm not sure which bushings I need or if there are others that I need as well?? I read over some of the shifter install how-tos and saw some bushing pics and info, but didn't see what I was looking for.

8 piece: http://www.lancershop.com/customer/p...cat=114&page=1

2 piece: http://www.lancershop.com/customer/p...cat=114&page=1

^^ are these the ones I need? Do I need anything else besides the shifter and 2pc, 8pc??

3) Down the road a bit I am looking to do the MIVEC light mod that otter has posted in the how to section. I am handy with electronics, so no worries with soldering etc., but the placement of the light.... I'm not too sure of. The links for the photos were dead... was wondering if you could snap a few pics (or post the old ones again) of the light mounted in the cluster??

4) I know I will need some rust remover compound to get those stubborn bolts loose on the downpipe and header. Anyone used something that stands out from the rest?

Please keep this thread clean as I will be using this thread for reference through many of my mods.... stay on topic, no hijacking, flaming, etc.
Pics. and writeup soon to follow.

 

Lancershop's phone people are just a hired out call center, they're rather useless. Yes, any shifter for the Evo 8 5 speed will work, same goes for those bushings, they're the right ones.

On the mivec light, I don't have the vid anymore. When I had the light (which wasn't long, couldn't get the relay to stop buzzing, was annoying as hell) I had a couple LEDs put in behind the "Lancer" logo in the cluster.

Hit the bolts with a wire wheel or wire brush, remove as much rust as you can, then hit them with PB Blaster and let them soak. After that, they should come off with an impact wrench. If you don't have air tools, you can try it by hand. Worst case, you're cutting the bolts off.

 

And if you do try to take the header bolts off make sure you still use an "impact" socket cause there on there tight enough where it would split a normal socket. Impact sockets are normaly black and heaver.

 

Surprisingly I didn't have any trouble at all getting the bolts off of mine. I used a regular socket wrench and the handle of a jack for more leverage on the more difficult ones. The installation of the new headers was a bit of a pain though. Had to temporarily remove a radiator fan to get enough clearance to slide the header into place.

 

Thanks for the tips. Since I do not own air tools I'll be doing this all by hand. I picked up some PB blaster. I have started the install today and will post pics when I'm done. I saw a general lack of pictures from the "O2 fix" thread.... since I will be doing that as well, I'll take some photos for those who may want some clarification.

 

The two bolts that are attached to the engine that hold the bracket for the bottom section of the stock header (right where it attaches to the stock downpipe with 3 bolts). Am I ok removing these 2 bracket bolts that go "into" the engine?

I recall reading a post regarding a bolt that was NOT to be removed that was in this area. I see a bolt just to the right of the bracket (when facing the engine looking straight down at the engine) .... perhaps this was the bolt that was NOT to be removed?

 

Neither of the bolts on the bracket are that bolt are the bolt to not mess with, but just the same, might as well leave the bracket on there, easier to avoid losing that way.

 

Here is a link that you might find useful......https://www.evolutionm.net/forums/04...-downpipe.html

I didnt find any of the bolts on the header hard to unbolt....but the bolts on the cat is another story...had to cut them babies off. oh btw header goes in from underneath, its a tight fit but possible, didnt have to remove the radiator fan. hope that helps

 

@ otter: Yeah right after I typed up the bolt question I took a 2nd look at it and realized that I didn't need to take those out to get it off, so I just left it on like you suggested. Also, the PB Blaster stuff worked great! I don't think I would have gotten those bolts off without it.

@ottomatic: THAT was the thread I read awhile back! I was looking for that earlier... I did a search for it and looked under the "how to" section, but I didn't look under the "tips and requests" portion of that section.
I didn't have any problems with any of the bolts besides the 2 x 19mm bolts. They were VERY stubborn, but with my dremel with a wire brush, 3 applications of PB Blaster and a breaker bar/impact socket with a 1/2 in. drive they came off with all the force I could muster from my legs... the exhaust was moving maybe 4 inches or so.
Also, I learned quickly that the header wouldn't go in from the top so that will probably take 2 people to put it in from the bottom.

Update: I have the old header/downpipe completely removed aside from the O2 sensor. I'm not to fond of splicing wires that are fairly exposed, and I looked for the notched socket at my local auto parts store with no success. So I think I might have to use a large wrench to get it off. It is kinda at an awkward angle....

 

did you see this thread?
https://www.evolutionm.net/forums/ev...cel-light.html

 

Looks like I need to look around some more. The only thread I saw was with no pictures. Thanks for the heads up.

The O2 sensor hole on the header... I need to get a plug for this, correct?

 

you have an 02 sensor in the header? i don't think we have one of those...

 

obx headers have that hole

 

ahh... i didnt see where in the thread he posted he has the obx ones...

then yes you need to plug that one... shoudln't they come with a plug when you bought it?

 

Yes I have the OBX header/DP, and no it did not come with a "plug" (although some may??). I had to go to a nuts and bolts manufact. To find the right bolt. Don't expect to find this at an auto parts or hardware store. Might want to make an additional note reguarding this in the header how to thread. I'll post the details in a later post.

Update: header and downpipe are installed, and it is LOUD!!! But this was expected so no worries. Also, O2 mod installed and successfull so far.