Best BBK Shorty Headers for 5.7 Hemi Charger & Challenger

If you own a 5.7L Hemi Charger or Challenger, a set of BBK shorty headers is one of the smartest first bolt-ons you can make. The factory cast-iron exhaust manifolds on the LX and LD platform cars are heavy, restrictive, and prone to warping (a leading cause of the dreaded "Hemi tick"). Swapping them for BBK's CNC-machined, mandrel-bent tuned-length shorties frees up trapped exhaust flow right at the cylinder head, wakes up the Hemi's midrange, and gives your V8 a deeper, more mechanical growl. At NLP Performance in Tampa, FL, Hemi headers are one of the most-shipped exhaust upgrades we stock — and this guide compares every BBK shorty option that fits the 5.7L, 6.1L and 6.4L Hemi so you can order the right part the first time.

How Much Horsepower Do Shorty Headers Add to a 5.7 Hemi?

BBK shorty headers add roughly 10–15 wheel horsepower and 15–20 lb-ft of midrange torque to a 5.7L Hemi, with the biggest gains showing up between 2,000 and 4,000 RPM where you actually drive. BBK advertises "up to 15–20 horsepower," and that upper figure is realistic on a fully warmed dyno with a supporting tune — but the honest, stock-tune, real-world number most owners see is in the low-to-mid teens at the wheels. We tell customers to expect a noticeable seat-of-the-pants improvement in throttle response and midrange pull rather than a dramatic top-end explosion.

Headers are a "system" modification: they breathe best when paired with a cold-air intake, a cat-back or high-flow mid-pipe, and an optional handheld tune. Stacked together, those mods can push a naturally-aspirated 5.7L into the low-to-mid 330-whp range. On their own, shorties are a modest but very real bump — and unlike long-tube headers, they do not require a tune to run cleanly. Because BBK shorties retain the factory catalytic converters and keep every oxygen sensor in its original location, they almost never trigger a check-engine light. That "install it and drive it" simplicity is exactly why shorties are the default header choice for daily-driven Hemi cars.

The Best BBK Shorty Headers for the Hemi Charger & Challenger

BBK builds a shorty header for every generation of Gen III Hemi in the LX/LD platform. The right part number depends on three things: your engine (5.7L, 6.1L or 6.4L), your model year, and your finish preference (Silver Ceramic or the higher-temp Titanium Ceramic). Here are the five we recommend most, starting with our overall top pick.

This is the header we recommend to most 5.7L R/T owners. The 1-3/4-inch primary tubes are perfectly sized for the naturally-aspirated 5.7L, the die-stamped 3/8-inch flange resists warping, and the polished Silver Ceramic coating both looks sharp and holds heat in the tube to preserve exhaust velocity. At $382.39 (down from $569.99), it is also the least expensive way into a genuine BBK header on this platform. New gaskets and hardware are included in the box.

Same tuned-length design as our top pick, but wrapped in BBK's darker matte Titanium Ceramic coating, which is rated for roughly 100°F more heat tolerance than the silver finish. If you want the best underhood temperature control and a stealthier grey look, this is the one to buy. At $432.02 it is a small premium over the silver version and fits the identical 2005–2015 5.7L application.

Later 2009–2020 5.7L Challengers use a slightly different application, and this is the correct BBK shorty for those cars. It carries the same 1-3/4-inch tuned-length tubing and Titanium Ceramic finish. If your Challenger is a 2015 or newer model, note that Chrysler encrypted the PCM starting around 2015 — another reason these no-tune shorties are so popular on newer cars where long-tube tuning requires an unlocked PCM.

Driving a 6.4L 392 Scat Pack? The bigger Hemi wants bigger tubes, and BBK steps the primaries up to 1-7/8 inches to match the extra displacement and airflow. Real-world gains on the 6.4L run a bit higher than the 5.7L — roughly 17–20 wheel horsepower with supporting mods. BBK builds the same 1-7/8-inch shorty for the 2005–2010 6.1L SRT8 (part 40130), so early SRT8 owners are covered too.

If you want the complete front-half exhaust in one box, BBK bundles the 1-3/4-inch header with a matching high-flow catted mid-pipe. Because it uses high-flow catalytic converters rather than deleting them, it flows far better than stock while keeping your emissions equipment intact. At $1,351.24 it is the premium pick for owners who want the biggest breathing improvement short of long-tubes without piecing parts together.

BBK Hemi Header Comparison Chart

Every header below is a genuine BBK shorty. Match the row to your engine and model year, then choose your finish. Prices are current NLP Performance pricing.

Silver Ceramic vs Titanium Ceramic: Which Finish Should You Buy?

Both BBK ceramic coatings do the same job — they form a thermal barrier that keeps heat inside the tube (which maintains exhaust velocity and power) while lowering underhood temperatures and resisting corrosion. The difference is heat rating and appearance. Silver Ceramic is a polished, chrome-like finish that looks great in a clean engine bay and is the most affordable option. Titanium Ceramic is a darker matte grey coating rated for roughly 100°F more heat tolerance, making it the better choice for hard-driven or forced-induction cars and anyone who prefers a stealthier look.

One important care note that many owners miss: do not wrap a ceramic-coated header. Header wrap traps moisture against the coating and will damage the finish — and BBK specifically excludes wrap-related damage from its warranty. If you want more heat protection, buy the Titanium Ceramic version rather than wrapping the silver one.

Shorty vs Long-Tube Headers: Which Is Right for Your Hemi?

Shorty headers are the bolt-on, daily-driver choice; long-tube headers are the tuned, top-end power choice. Shorties keep the factory catalytic converters and oxygen-sensor locations, so they run cleanly with no tune and rarely throw a check-engine light — but they make roughly half the power of long-tubes, concentrated in the low and midrange. Long-tube headers add substantially more top-end horsepower (often 25–35 whp on a 5.7L with a tune), but they replace the factory cats, require a custom tune to disable the rear oxygen sensors, and will set a check-engine light if left untuned.

For most Charger and Challenger owners who drive their car on the street, shorties win on cost, legality, and simplicity. Long-tubes make sense on a dedicated, already-tuned build. One more consideration for 2015-and-newer cars: Chrysler's encrypted PCM means long-tube tuning requires an unlocked PCM, adding cost and hassle that shorties completely sidestep. Browse our full exhaust collection if you want to pair headers with a cat-back for the complete sound-and-power package.

What to Expect When Installing BBK Shorty Headers

Plan on a moderate 3–5 hour DIY job with hand tools, a floor jack, and jack stands. BBK includes new gaskets and header bolts in the kit, so you have the hardware you need. On the LX/LD Hemi cars there are two access points that catch people off guard: the passenger-side header usually goes in easiest with the engine raised slightly off the mount, and the driver-side install requires unbolting the steering shaft and moving it aside for clearance. Reinstall your factory oxygen sensors into the new headers, and use a dab of anti-seize on the top threads — one sensor can be tight to start. Because the factory cats and sensor locations are retained, no tune or oxygen-sensor spacers are required to run cleanly.