Broken Kooks Headers

[El_Dude]

These are the headers I had: 35101110 (KKH) Kooks Custom Headers Stainless Steel Torque Shorty Headers

I installed them in 2021. Earlier this year, I started hearing a ticking noise and it got louder as time went by. After an inspection I noticed a hairline crack on one of welds in the passenger side header. I removed it and noticed it way cracked inside. See attached pictures.
Not sure how long these usually last but 3.5 years seems way to short. I've sinced replaced them with the DB Diesel manifolds and all is quiet. Installation of the BD's was a breeze too.

Anyone else seen Kooks break like this?

 

[kirk35]

That's just poor craftsmanship. The **** of a weld on the outside of the collector was way too cold, resulting in a lack of fusion to the base metal. The weld inside the tube failed because they didn't use any filler wire, they just ran a tig torch over the header tube and fused it to the flange. You would think for the price of Kooks they would weld things properly.

 

[El_Dude]

Ah thanks for that insight. I don’t know anything about welding. Yeah I paid I think 1100 for these.

 

[chopperman1]

Kooks has a lifetime warranty, did you contact them? I had an issue with a weld many years ago, the customer service person had me send a few close up picture. Called me back about 30min later and said yes it's warranty. I did have to send the old one back after I received the replacement. They even did a pre-paid ship label for me.

 

[El_Dude]

I have not. I will look into that.

 

[El_Dude]

Ok I just submitted a claim with Kooks. I purchased them from a distributer called Unique Auto Depot but looks like the company closed down as the website is no longer accessible. Wonder what if anything comes of this. Would be nice recoup some of that money. I'll keep yall posted.

 

[Mb7640]

These are the headers I had: 35101110 (KKH) Kooks Custom Headers Stainless Steel Torque Shorty Headers

I installed them in 2021. Earlier this year, I started hearing a ticking noise and it got louder as time went by. After an inspection I noticed a hairline crack on one of welds in the passenger side header. I removed it and noticed it way cracked inside. See attached pictures.
Not sure how long these usually last but 3.5 years seems way to short. I've sinced replaced them with the DB Diesel manifolds and all is quiet. Installation of the BD's was a breeze too.

Anyone else seen Kooks break like this?

Just curious is there a reason why you did not go with afe? I have been considering shorty headers and have been leaning towards afe.

 

[El_Dude]

There are several companies that make headers and manifolds and I just chose based on reviews on this forum and Google searches. I don’t have any experience with afe so I couldn’t say either way if they’re good or not.

 

[Hanover Fiste]

I had a set of Kooks headers on my '95 Thunderbird SC, and they leaked from the very beginning. The dealer would only exchange them if I shipped them the old headers first. If the problem was verified, then they would send out a new set. All that would take a week or two, but I needed my car, so I just had a local welding shop repair the leak on my dime. Fortunately, it wasn't expensive.

 

[andymax]

Just curious is there a reason why you did not go with afe? I have been considering shorty headers and have been leaning towards afe.

Why are you leaning towards AFE? I may be facing this decision so I'm curious. Depending on OP's warranty claim result that may be one click towards the Kooks if they do right by him.

 

[Bigskyroadglide]

My afes shorties were a breeze to install, work well, were easy to wrap and cost less than kooks. I also caught them on a holiday sale, so they were a decent deal.

 

[theblackduck87]

I had the very same thing happen to my BBK shorties. Turns out after I got the 1st set warranted, installed the 2nd set, had it happen again, sprung for SW long tubes, I found an exhaust shop near me that could've solved the problem by splitting my factory Y and patching the seam. Go figure.

 

[Mb7640]

Why are you leaning towards AFE? I may be facing this decision so I'm curious. Depending on OP's warranty claim result that may be one click towards the Kooks if they do right by him.

I am leaning towards afe from what I have read they seem like a solid company. I know they are more expensive but quality normally is. From my challenger 5.7l days I read that Jba and kooks have a lot of issues so I was not really looking at them. On one of my challengers I had american racing long tube headers and they were solid. If they made shorty's I would go with them.Im not going the long tube route again due to emission testing where I am at. I did not care on the challenger because I knew I would be trading it in before I had to deal with emission testing. For me it depends if I can get my extended warranty extended from 75k miles to 150k miles. If zi can I will hold off on the header for a few more years. If not i will have to do it sooner. I will be at 75k miles probably by January

 

[chri5k]

Kooks doesn't even weld all the way around the pipe where it meets the flange?? Seems like they are almost guaranteed to leak and crack. I guess they do live up to their name.

 

[kirk35]

Kooks doesn't even weld all the way around the pipe where it meets the flange?? Seems like they are almost guaranteed to leak and crack. I guess they do live up to their name.

The weld that seals the tube to the flange is on the inside of the tube. The weld on the outside is there for strength. Unfortunately in the OP’s case both welds failed.

 

[chri5k]

The weld that seals the tube to the flange is on the inside of the tube. The weld on the outside is there for strength. Unfortunately in the OP’s case both welds failed.

As mentioned earlier, the inside "weld" looks more like they just ran the TIG torch over it with no filler wire. Or they did weld it and then ground most of it off when leveling the flange. Either way, it is not really the way to weld two different thicknesses of metal in a high heat area that will expand at different rates. Most other quality header manufacturers weld a complete bead around the outside.

 

[Black1500Ram]

Just curious is there a reason why you did not go with afe? I have been considering shorty headers and have been leaning towards afe.

FWIW I’m dealing with the exact same thing on my AFE shorties.

 

[Mb7640]

FWIW I’m dealing with the exact same thing on my AFE shorties.

Well thats not good maybe i will just keep the original manifolds ans see what happens

 

[El_Dude]

Yeah, it’s been talked about a lot on this forum. Either wait till they warp and get them cut down on the belt sander. Or replace them with something else. Or have the dealer replace them every time under warranty. Pretty much those are the options.
The BD diesel manifolds are about 500 bucks and while I’ve only had them on for a few days, the quieted my truck are very easy to put on. They come with new bolts and gaskets.

 

[Mb7640]

Yeah, it’s been talked about a lot on this forum. Either wait till they warp and get them cut down on the belt sander. Or replace them with something else. Or have the dealer replace them every time under warranty. Pretty much those are the options.
The BD diesel manifolds are about 500 bucks and while I’ve only had them on for a few days, the quieted my truck are very easy to put on. They come with new bolts and gaskets.

$500 is not bad I dont like that it makes the truck quiet. I do understand that all manufacturers of headers will have issues sooner or later with some of their products . Nowadays maybe more often then not which is a shame. Lucky for me i still have time under my extended warranty not much time thats why I have been debating on what I will do. Let us kniw how these work out for you hopefully no issues.