[blykins]

Got the header problem solved. Dana was very cooperative and they actually sent me a couple of sets to try....even a custom set. After it was all said and done, they sent me some header tubes and I lengthened and shaped the header as needed. Works and looks perfect. I honestly don't have a clue as to what was up with that. It's a mystery.

I just re-read your post.....the clearance issue is fixed also. There's quite a bit of room between the header and the steering shaft.

There's got to be something else that's causing your problem.....I'm sure it may be heat related as you said the heat shield calmed it down a little. However, I've seen headers that wrapped around the steering shaft....and I've seen headers that come within a 1/2" of the shaft. There's got to be some little thing that we're overlooking. How hot is your engine compartment? Headers coated? Engine isn't running lean is it?

I won't have to worry about the brake fluid problems...my master cylinders are mounted inside on my floor mounted pedals....and the resevoirs are on the firewall.