aFe Twisted Steel Headers — Jeep Wrangler JK 3.8L, 409 Stainless

Twisted Steel 409 stainless header pair for Wrangler JK gas V6 3.8L

The aFe 48-48023 Twisted Steel header pair uses 1.5-inch 14-gauge mandrel-bent 409 stainless tubing, mitered collectors, hand MIG welding and 3/8-inch flanges. It connects at factory mounting locations while retaining the stock catalytic converters. Current manufacturer copy expressly sells gasket kit 48-90004 and spark-plug boot protectors 48-90001 separately; they are not automatically included with the header pair.

Key Features

• Selected aFe part 48-48023.
• Documented Wrangler JK 2007–2011 gas V6 3.8L applications only; no 3.6L or later-model inference.
• 1.5-inch 14-gauge 409 stainless primary tubes, mitered collectors and hand MIG welding.
• 3/8-inch head flanges and factory mounting locations; manufacturer describes bolt-on installation without cutting or drilling.
• One left header 05-44790 and one right header 05-44794 with four flange bolts and four flange nuts.
• Gasket kit 48-90004 and spark-plug boot protectors 48-90001 are separate recommended purchases. Keep all plug wires and protector boots off the header tubes.
• Retains stock catalytic converters but is NOT currently CARB exempt; manufacturer excludes California purchase and use on California-DMV-registered vehicles.

Fitment

Current exact manufacturer application is Wrangler JK 2007–2011 gas V6 3.8L. The complete exact-MPN named table supports all ten named rows below; the missing Unlimited Sahara 2007–2011 group is restored. A trim name is not approval of another engine. Keep the factory catalysts, verify installed equipment and obey the manufacturer’s emissions restrictions before purchase or installation.

Specifications

What's Included

• The 48-48023 kit includes one left header 05-44790 and one right header 05-44794.
• Four flange bolts 05-40104 and four flange nuts 05-40103. Original cylinder-head fasteners are reused.
• Gasket kit 48-90004 and spark-plug boot protectors 48-90001 are separate recommended purchases, not established supplied contents. Resolve the guide’s gasket provided wording against the actual packing list before installation.
• No catalytic converters, replacement downpipes, exhaust tips, intake filter, intake coupling or numerical-torque specifications are included in the selected formal list.

About aFe Power

aFe Power develops application-specific intake, filtration, exhaust, cooling, tuning, suspension, drivetrain, and truck-performance components supported by product testing and documented installation requirements.

Related Parts

• Exact selected header pair, separate accessories and emissions restriction
• Complete selected 17-step guide, parts list and source limitations
• Complete exact-MPN named application table
• Shop headers and manifolds
• Shop aFe Power

FAQ

It is a pair of MIG-welded 409 stainless exhaust headers for documented 2007–2011 Wrangler JK gas V6 3.8L applications, using factory connections and retaining stock catalysts.

Current exact manufacturer copy expressly sells gasket kit 48-90004 and boot protectors 48-90001 separately; neither appears in the formal included-parts list. Step 11 says gasket provided, so confirm actual packing contents with aFe before work rather than assuming a gasket is included.

This exact selection is documented for 2007–2011 JK gas V6 3.8L. No later 3.6L engine, different flange, installation procedure or gasket is inferred from shared Wrangler branding.

Yes. The formal list contains left header 05-44790, right header 05-44794, four flange bolts 05-40104 and four flange nuts 05-40103. Original cylinder-head bolts are reused.

Resolve gasket supply, the guide’s missing initial battery-disconnect step and its unprinted final heat-shield disposition with aFe and exact vehicle service information. Step 16 reconnects the negative battery terminal, but that does not supply the missing initial procedure.

Mark each wire before removal, reinstall it in its original position and prevent wire or protector-boot contact with the header tubes. The manufacturer recommends the separately purchased boot protectors. No fixed clearance measurement is printed.

No. The current manufacturer says this selection is not CARB exempt and excludes California purchase and use on California-DMV-registered vehicles. Do not substitute a blanket 49-state claim or infer approval from a different header.

Tighten original head bolts from the middle outward; use threadlocker on the supplied downpipe flange hardware as the guide directs. No numerical torque, threadlocker grade or mileage recheck interval is printed. The 6 hp/6 lb-ft maximum-gain figures remain primary claims with exact test conditions unlocated.

Installation Instructions

1. Confirm aFe 48-48023 against the exact vehicle and installed equipment. Inventory the actual components and follow the selected manufacturer instructions and current vehicle service requirements.
2. Read the complete selected 17-step guide and confirm the exact 2007–2011 JK gas V6 3.8L application and emissions eligibility. Resolve actual gasket supply, initial battery isolation and final heat-shield disposition with aFe/exact vehicle service information before starting; those details are inconsistent or incomplete in the selected guide.
3. Allow the exhaust to cool, use protective equipment and safely support the vehicle. Remove both inner-fender splash guards and both downpipe-to-original-manifold attachment bolts.
4. Mark the spark-plug wires so each can return to its original plug, then remove the wires. Remove the right manifold heat shield, right manifold and right gasket, taking care not to damage spark plugs. Preserve a reusable gasket carefully if that is the confirmed applicable arrangement.
5. Remove the left manifold heat shield, left manifold and left gasket with the same plug/gasket care. Both original manifolds are removed through the wheel-well openings. The guide does not supply a final heat-shield restoration step; use the arrangement confirmed before work.
6. Install the right aFe header and confirmed correct gasket through the fender-well opening using original head bolts. Tighten from the middle outward. Install the left header and confirmed gasket the same way. Current primary sells replacement gaskets separately despite step 11’s provided wording.
7. Connect the right downpipe first and then the left with the supplied flange bolts/nuts and threadlocker as the selected guide directs. The guide does not identify a threadlocker grade or numerical torque.
8. Reinstall each marked spark-plug wire in its original location. Fit the separately selected recommended boot protectors as applicable, and adjust wire routing so neither wires nor boots directly contact the header tubes. No fixed clearance dimension is printed.
9. Reinstall both inner-fender splash guards. Restore any battery isolation using the exact arrangement confirmed before work; the selected guide’s step 16 reconnects the negative terminal but omits an initial disconnect step. Recheck all work. No cutting, drilling, catalyst deletion, fuel-line service, engine-hoist operation or mileage recheck interval is borrowed from another header.

California Proposition 65 warning: this product can expose you to chemicals known to the State of California to cause cancer and reproductive harm.