Maybe bash that tube in a little bit. I think the physics of the heat radiating off the tube follows the inverse square law, so even creating just a little bit more distance can have a large impact.
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I was using a 4L60E so maybe that’s the difference6.0l and 6l80e
It has to be the motor mounts and 1500/2500 difference. The trans won’t make a difference on where the collector is.I was using a 4L60E so maybe that’s the difference
That may be on Van frames, but on truck frames you just drill new holes. I was able to slot my crossmember where the trans mount is. That gave me enough adjustment to use the original frame holes. But as far as the header clearance on a 2500 the long tubes clear and will need to be Jet Hotted or similar ceramic coating. Wrap may work but with the flex of the engine my guess is the joint count chew into it under torque load.Another thing, the transmission absolutely can make a difference IF you are using adjustable mounts and locating the engine in relation to the transmission crossmember and transmission mounting point. In regard to bellhousing face to mount, the 6L80E is slightly longer than the newer 4L60Es and substantially longer than the older 4L60Es. The mounting point on the newer 2 piece bellhousing 4L60Es moved compared to the older 700r4/1-piece bellhousing 4L60Es. Because of this I actually bought a 1998-2002 Express 4L60E crossmember for my future 6spd automatic swap in my 97 van. The newer crossmember bends slightly to the rear for the longer 2 piece 4L60E used in those vans and matches the 6L mounting postion well.
My point was more if the crossmember was left in stock location and the 6spd bolted to it that the engine would be in a different position than the headers were designed to fit in.That may be on Van frames, but on truck frames you just drill new holes. I was able to slot my crossmember where the trans mount is. That gave me enough adjustment to use the original frame holes. But as far as the header clearance on a 2500 the long tubes clear and will need to be Jet Hotted or similar ceramic coating. Wrap may work but with the flex of the engine my guess is the joint count chew into it under torque load.