The 5.7 HEMI engine is one of the most popular and versatile power plants in the modern performance world. Found in everything from the Dodge Charger and Challenger to the Jeep Grand Cherokee and Ram 1500, this engine responds well to basic bolt-on modifications. Among the most impactful upgrades you can make is replacing the factory exhaust manifolds with aftermarket headers. The stock manifolds are restrictive, with small-diameter tubing and catalytic converters built into the design on many models. Swapping to a set of performance headers can unlock significant horsepower and torque, improve throttle response, and give your HEMI a more aggressive exhaust note.

But with several brands on the market, choosing the right set of headers for your build can be overwhelming. Each brand has its own strengths, price points, and fitment characteristics. In this comparison, we will take a deep dive into four of the most prominent header manufacturers for the 5.7 HEMI: Kooks Custom Headers, American Racing Headers (ARH), BBK Performance, and Hooker Headers. We will evaluate each brand across three critical categories — power gains, cost, and installation ease — so you can make an informed decision that matches your budget and performance goals.

Header Basics: Long-Tube vs. Shorty Headers

Before jumping into brand comparisons, it is important to understand the two primary types of headers available for the 5.7 HEMI: long-tube and shorty (also called mid-length) headers. The choice between these two designs affects power delivery, emissions compliance, and installation complexity.

Long-tube headers have primary tubes that are typically 30 to 36 inches long, merging into a collector well downstream of the cylinder head flange. This design optimizes exhaust scavenging at mid-range and high RPM, producing the largest peak horsepower gains — often 20 to 30 HP or more on a 5.7 HEMI. However, long-tube headers relocate the catalytic converters (if you choose to run them) further downstream, which can trigger check engine lights and may require a custom tune. Most long-tube installations also require removing the factory starter and sometimes modifying the transmission dipstick tube or steering shaft clearance. They are not legal for use on vehicles that must meet CARB (California Air Resources Board) emissions standards when they eliminate or move the factory catalytic converters.

Shorty headers (sometimes called “shorties”) have shorter primary tubes that connect directly to the factory catalytic converter location. They are a direct bolt-on replacement for the stock manifolds and are often 50-state legal because they maintain the original emissions equipment placement. Shorty headers offer more modest power gains, typically 5 to 15 HP, but they are much easier to install and do not require a tune in most cases. They also fit most vehicles without needing to relocate the starter or modify other engine bay components.

The brands we cover in this article offer both long-tube and shorty options, but Kooks, ARH, and Hooker are best known for their long-tube designs, while BBK is popular for its shorty headers. Your choice depends on how much power you want, your budget, and your local emissions laws.

1. Kooks Custom Headers

Company Background and Product Range

Kooks Custom Headers, founded by George “Kook” Kokkonis in 1985, is a Long Island, New York-based manufacturer that has earned a reputation for building some of the best custom headers in the industry. They specialize in mandrel-bent, 304 stainless steel headers for a wide range of American muscle cars, trucks, and late-model performance vehicles. For the 5.7 HEMI, Kooks offers both catted and catless long-tube headers, as well as a selection of mid-length headers for certain applications. Their headers are hand-welded, fully TIG-welded for strength and durability, and are available with a choice of 1⅞-inch or 2-inch primary tube diameters depending on your engine combination.

Power Gains

Kooks long-tube headers are among the best in the business for extracting power from the 5.7 HEMI. On a otherwise stock engine, independent dyno tests have shown gains of 18 to 25 horsepower and 15 to 20 lb-ft of torque at the rear wheels. When combined with a cold air intake, a performance tuner, and a cat-back exhaust system, the total gain can push 30 to 40 HP. The design of Kooks headers focuses on equal-length primary tubes and smooth collector transitions, which helps maintain strong torque across the entire RPM band without sacrificing top-end power. Many owners report that the HEMI feels significantly more responsive from 3,000 RPM upward, and the engine pulls harder well into the 6,000 RPM range.

Cost and Value

Kooks headers sit at the premium end of the price spectrum. A set of stainless steel long-tube headers for a 5.7 HEMI Challenger or Charger typically costs between $1,200 and $1,600, depending on whether you choose catted or catless versions and whether you opt for a ceramic coating. Add another $200 to $300 for optional high-flow catalytic converters or off-road connection pipes. For many enthusiasts, the price is justified by the build quality, the use of premium 304 stainless steel (which resists corrosion and discoloration better than 409 stainless), and the fact that these headers are made in the U.S.A. with a reputation for exacting fitment. If you intend to keep your vehicle for a long time and want headers that will look and perform well for years, Kooks is a strong contender.

Installation Ease

Kooks headers are designed to be a direct fit for most 5.7 HEMI applications, but “direct fit” still involves a challenging job. You will need to remove the factory exhaust manifolds, unbolt the starter motor (and often relocate it with a supplied bracket), and in some cases, remove spark plugs to access the header bolts. On AWD models like the Jeep Grand Cherokee or Dodge Durango, clearance is tighter, and you may need to drop the front differential or remove the front driveshaft to get the headers into place. Depending on your skill level and tools, plan for a full weekend for the job. Kooks includes new gaskets and hardware, but you should also plan to buy replacement exhaust manifold bolts (which often break during removal on high-mileage HEMIs). Overall, installation difficulty is moderate to high, and many owners choose to have a professional shop do the work.

Pros and Cons

Pros: Exceptional power gains; premium 304 stainless steel construction; hand-welded quality; good fitment for most models; available with or without cats; strong resale value.

Cons: High price point; installation is time-consuming and may require professional help; not CARB-legal in most long-tube configurations; may require a tune to avoid check engine lights.

2. American Racing Headers (ARH)

Company Background and Product Range

American Racing Headers (ARH), based in Long Island, New York (just like Kooks), is another top-tier manufacturer that competes directly with Kooks. ARH was founded by Nick Filippides and has built a reputation for custom-fit headers that are used by professional race teams and serious street enthusiasts alike. ARH offers a full line of long-tube headers for the 5.7 HEMI platform, including versions for the Charger, Challenger, 300, Magnum, Jeep Grand Cherokee, and Ram trucks. They are known for their signature “ARH” engraved flanges and their use of heavy-duty 304 stainless steel. ARH also sells complete exhaust systems, including X-pipes, mufflers, and cat-back kits, all designed to work together for maximum flow.

Power Gains

ARH headers consistently produce some of the highest peak power numbers on the 5.7 HEMI. Independent testing on a 2015 Dodge Challenger R/T with a 5.7 HEMI showed a gain of 22 horsepower and 18 lb-ft of torque at the rear wheels with just ARH long-tube headers and a tune. When paired with an ARH cat-back exhaust and a cold air intake, the total gain reached 35 HP. The primary tubes on ARH headers are typically 1⅞-inch for most 5.7 applications, but they also offer a 2-inch option for heavily modified engines with forced induction or cam upgrades. The design of the collector is particularly well-engineered, with a smooth merge that reduces turbulence and helps maintain exhaust velocity. Drivers report a noticeable improvement in mid-range punch and a louder, more aggressive exhaust note that still retains a civilized idle when cruising.

Cost and Value

ARH headers are priced similarly to Kooks, with many sets falling between $1,300 and $1,800. If you add the optional ceramic coating (which helps reduce underhood temperatures and prevents surface rust), expect to pay an additional $200 to $300. ARH does not offer a “budget” line, so you are paying a premium for materials and craftsmanship. However, many owners feel the price is justified by the precise fitment and the fact that these headers are made to order in the U.S. ARH also offers a limited lifetime warranty on their stainless steel headers, which adds peace of mind for a long-term investment.

Installation Ease

ARH headers are designed to fit without major modifications, but like any long-tube header on a 5.7 HEMI, the installation is not a beginner-level job. The company provides detailed instructions, but you will still need to deal with tight clearance around the steering shaft, the starter, and the transmission dipstick tube on some models. The flanges are machined flat for a good seal, and ARH includes quality gaskets and fasteners. One advantage ARH has over some competitors is that their headers are often reported to fit more easily on Ram 1500 trucks and Jeep Grand Cherokees, where clearance is even tighter. Still, expect to spend 6 to 10 hours if you are experienced, or longer if you run into rusted bolts. A professional installation typically costs between $400 and $700 in labor.

Pros and Cons

Pros: Outstanding power gains; high-quality 304 stainless steel; made in the U.S.A.; good fitment across multiple platforms; lifetime warranty; works well with ARH exhaust systems.

Cons: Expensive; long lead times on custom orders (often 4 to 8 weeks); not CARB-legal long-tube versions; installation requires patience and mechanical skill; no budget-friendly option.

3. BBK Performance Headers

Company Background and Product Range

BBK Performance, headquartered in Corona, California, is a well-established company that has been making aftermarket performance parts since 1974. They offer a wide range of products including throttle bodies, intake spacers, cold air intakes, and exhaust components. For the 5.7 HEMI, BBK is best known for their shorty headers, which are designed as a direct replacement for the factory exhaust manifolds. BBK also offers long-tube headers for some HEMI applications, but their shorty headers dominate the market because of their affordability and ease of installation. BBK’s headers are made from 409 stainless steel or 304 stainless steel depending on the specific part number, and they are available with either a natural steel finish or a ceramic-coated finish.

Power Gains

BBK shorty headers deliver modest but noticeable power gains on the 5.7 HEMI. Because shorty headers replace only the manifold section and retain the factory catalytic converter location, the flow improvement is less dramatic than long-tube designs. Most dyno tests show gains of 8 to 14 horsepower at the rear wheels, with a corresponding increase of 6 to 10 lb-ft of torque. The torque gain is often felt low in the RPM range, which can make the engine feel slightly more responsive during daily driving. On paper, these numbers are not as impressive as Kooks or ARH, but for many owners, the power gain is enough to make the vehicle feel more lively without the expense and hassle of a full long-tube system. If you are planning to install a camshaft or forced induction later, you may want to skip shorties and go straight to long-tubes, but for a daily driver with light modifications, BBK shorties offer a solid improvement.

Cost and Value

BBK shorty headers are among the most affordable options for the 5.7 HEMI. Pricing typically ranges from $400 to $800 for a set of shorty headers. The ceramic-coated versions are at the higher end of that range, but they still come in well under the cost of Kooks or ARH long-tubes. For the price, you get a well-engineered product that fits most models without major modifications. BBK also sells catted versions that include high-flow catalytic converters, which can add another $200 to $300 but keep the check engine light off in some situations. If you are on a tight budget or plan to sell your vehicle soon and want to recover your investment, BBK shorties offer the best bang for the buck.

Installation Ease

This is where BBK really shines. Because BBK shorty headers are designed to mount directly to the cylinder head and bolt up to the factory catalytic converter pipes, installation is straightforward for anyone with basic mechanical skills. On most 5.7 HEMI vehicles, you can complete the job in 4 to 6 hours in a home garage with a basic socket set. You do not need to relocate the starter, modify the steering shaft, or cut any pipes. The headers come with new gaskets and bolts, and the flanges are laser-cut for a precise fit. For DIY enthusiasts who want to install headers without having to pay a shop, BBK is by far the easiest option among these four brands. Even on high-mileage vehicles where the manifold bolts are corroded, the job is manageable with penetrating oil and the right tools.

Pros and Cons

Pros: Affordable price point; easy DIY installation; direct bolt-on design; available in 409 or 304 stainless steel; ceramic coating option; 50-state legal in most configurations (check your specific part number); good for daily drivers.

Cons: Lower power gains compared to long-tube headers; not ideal for high-horsepower builds; 409 stainless steel can rust over time if not coated; limited to shorty designs for most HEMI applications; less aggressive exhaust tone.

4. Hooker Headers

Company Background and Product Range

Hooker Headers is one of the oldest names in the performance exhaust industry, with roots dating back to the 1960s. Now owned by Holley Performance Products, Hooker produces a wide range of headers for everything from classic muscle cars to late-model trucks and SUVs. For the 5.7 HEMI, Hooker offers both shorty and long-tube header options, including their popular Blackheart series for trucks. Hooker headers are made from 304 or 409 stainless steel, with ceramic coating available on many models. The company is known for offering good performance at a price point that is more accessible than premium boutique brands like Kooks and ARH.

Power Gains

Hooker long-tube headers for the 5.7 HEMI deliver power gains that are competitive with Kooks and ARH in many cases. Dyno results from various sources show gains of 15 to 25 horsepower at the rear wheels on a stock engine, with torque improvements of 12 to 18 lb-ft. The Hooker Blackheart long-tube headers for Ram trucks are particularly well-regarded, with owners reporting solid gains even on heavy 4x4 models. Hooker shorty headers offer more modest gains similar to BBK, typically in the 8 to 15 HP range. One area where Hooker excels is in their collector design — they use a stepped collector that helps maintain exhaust velocity and improve low-end torque, which is beneficial for daily driving and towing applications. If you are building a truck or SUV that sees both street and off-road use, Hooker headers strike a good balance between power and driveability.

Cost and Value

Hooker headers offer a compelling value proposition. Long-tube sets typically range from $700 to $1,200, which is significantly less than Kooks or ARH but still delivers comparable power gains. Shorty headers from Hooker are even more affordable, often falling between $500 and $900. The Blackheart series, which is designed specifically for trucks and features a black ceramic coating, is priced at the higher end but still undercuts the premium brands by several hundred dollars. For the price, you get a well-built header that is backed by Holley’s customer support network, which is a plus if you have fitment questions or need warranty assistance. If you want long-tube performance without paying Kooks or ARH prices, Hooker is the strongest alternative.

Installation Ease

Installation of Hooker headers varies depending on which model you buy. Hooker long-tube headers generally require the same level of effort as Kooks and ARH — you will need to remove the starter, work around the steering shaft, and possibly modify the dipstick tube. However, many owners report that Hooker headers fit slightly better on Ram trucks and Jeep Grand Cherokees compared to some competitors, likely because the company has invested in platform-specific tooling. Hooker shorty headers, like BBK, are a much easier install and can be done in an afternoon. Hooker includes detailed instructions and all necessary hardware, and the gaskets are high-quality. For the average enthusiast, the installation difficulty is moderate — expect to spend 5 to 8 hours on long-tube headers or 3 to 5 hours on shorty headers if you are experienced.

Pros and Cons

Pros: Good power gains for the price; long-tube and shorty options available; solid build quality; backed by Holley; good fitment on trucks and SUVs; ceramic coating options; price is lower than Kooks and ARH.

Cons: 409 stainless steel models can rust if not coated; not all models include hardware; fitment on some passenger car models can be tighter than advertised; installation of long-tube versions still requires significant labor; not as much brand prestige as Kooks or ARH.

Long-Tube vs. Shorty: Which Header Style is Right for You?

If you live in a state that follows CARB (California, New York, Maine, etc.), your header options are limited. Long-tube headers that relocate or remove catalytic converters are not street legal in these states, which means you may fail a visual inspection or emissions test. Shorty headers from BBK or Hooker that retain the factory cat location are typically 50-state legal and carry an EO (Executive Order) number. If you are building a track-only car or a weekend toy and emissions are not a concern, long-tube headers from Kooks, ARH, or Hooker will give you the most power.

Daily Driving vs. Performance Builds

For a daily driver that sees stop-and-go traffic, shorty headers (BBK or Hooker shorties) are the more practical choice. They do not require a tune, they keep the check engine light off, and they do not significantly change the exhaust volume at idle. They also maintain ground clearance on lowered vehicles. For a dedicated performance build, weekend warrior, or track car, long-tube headers are the clear winner. The extra horsepower and torque at higher RPMs will make the car significantly faster, and the more aggressive exhaust sound adds to the experience.

Future Modifications

Consider your long-term build plan. If you are planning to install a camshaft, upgrade the intake manifold, or add a supercharger down the road, long-tube headers will flow enough for those upgrades. Shorty headers may become a bottleneck once you start making more than 450 to 500 horsepower. Investing in long-tube headers now can save you from replacing them later. On the other hand, if you plan to keep your HEMI mostly stock or with only minor bolt-ons, shorty headers will suffice and cost much less.

Installation Tips for 5.7 HEMI Headers

Regardless of which brand you choose, installing headers on a 5.7 HEMI is a challenging job. Here are some practical tips to make the process smoother:

  • Soak the manifold bolts in penetrating oil for 24 hours before you start. The factory bolts on high-mileage HEMIs are notorious for snapping. Use a quality product like Kroil or PB Blaster.
  • Replace the exhaust manifold bolts with new ones from the header manufacturer or a high-quality aftermarket set. Stretch bolts should not be reused.
  • Remove the spark plugs before you try to unbolt the manifolds. This gives you more room to reach the upper bolts.
  • Disconnect the battery and remove the starter motor on most long-tube installations. Some kits include a starter relocation bracket; use it.
  • Check clearance on the steering shaft on Charger and Challenger models. You may need to loosen the shaft or adjust the position to prevent contact with the header tubes.
  • Use anti-seize compound on all header bolts to make future removal easier.
  • Apply a thin bead of high-temp RTV to both sides of the header gaskets to prevent leaks, especially on long-tube installations where the header weight can cause gasket movement.
  • Plan for a tune if you install long-tube headers. An aftermarket tuner (like DiabloSport or HP Tuners) will let you disable the rear O2 sensors and optimize the air-fuel ratio for the improved exhaust flow.

Header Gaskets: Do Not Skimp

The gasket that seals the header to the cylinder head is critical for preventing exhaust leaks and maintaining performance. All four brands include gaskets with their headers, but quality varies. Kooks and ARH use multi-layer steel (MLS) gaskets that are reusable and compress evenly for a leak-free seal. BBK and Hooker typically include composite or graphite gaskets that work well but may need to be replaced if you remove the headers later. Many experienced owners recommend upgrading to a set of Remflex or Fel-Pro PermaTorque gaskets regardless of the brand, as these are known for superior sealing on HEMI engines where the cylinder head surface can be uneven. A gasket set costs $30 to $50 and is cheap insurance against leaks.

Coating Options: Ceramic vs. Natural Stainless

Headers come in two basic finishes: natural stainless steel or ceramic coated. Natural stainless steel (either 304 or 409 alloy) has a raw metallic appearance that can blue or discolor over time due to heat cycles. Ceramic coating is applied to the interior and exterior surfaces and provides several benefits:

  • Lower underhood temperatures by reflecting radiant heat away from the engine bay. This can reduce intake air temperatures by 10 to 20 degrees Fahrenheit.
  • Protection from corrosion and rust, especially important on 409 stainless steel which can oxidize over time.
  • Improved durability against stone chips and road debris.
  • Aesthetic appeal with a consistent black, silver, or titanium finish that does not discolor.

Kooks, ARH, and Hooker offer ceramic coating as an option for an additional $150 to $300. BBK offers ceramic-coated shorty headers for about $100 more than the natural steel version. If you live in the Rust Belt or plan to drive your HEMI in wet conditions, ceramic coating is a worthwhile investment. For a garage queen or track-only car, natural stainless steel is fine and saves money.

Tuning Requirements for Long-Tube Headers

One factor that many first-time header buyers overlook is the need for a custom tune after installing long-tube headers. The increased exhaust flow changes the scavenging characteristics of the engine and can cause the oxygen sensors to read a leaner air-fuel mixture. This often triggers a check engine light (P0420, P0430) indicating catalyst inefficiency. Even on catted long-tube setups, the rear O2 sensors may see different values than stock.

A proper tune from a reputable shop using HP Tuners or a handheld tuner like DiabloSport will:

  • Disable the rear O2 sensor codes to turn off the check engine light.
  • Adjust the fuel tables to correct any lean or rich conditions.
  • Optimize ignition timing for the improved exhaust flow.
  • Improve throttle response and shift points on automatic transmissions.

Shorty headers, by contrast, do not usually require a tune because they maintain the stock O2 sensor position and catalytic converter location. If you want headers but want to avoid the hassle and expense of a tune ($300 to $500), shorties are the way to go.

Which Header Brand Should You Choose?

Best for Maximum Power: Kooks or ARH

If your goal is to extract every possible horsepower from your 5.7 HEMI and budget is not your primary concern, Kooks and ARH are the top choices. Both brands use premium materials, hand-welded construction, and offer custom options for heavily modified engines. The difference between them is small — Kooks has a slightly longer warranty on some models, while ARH offers a lifetime warranty. The decision often comes down to personal preference and which brand’s fitment has been better reviewed for your specific vehicle. Both will deliver the best power numbers on a dyno.

Best Value: Hooker

For the enthusiast who wants long-tube performance without spending $1,500 or more, Hooker offers the best balance of power, quality, and price. The Hooker Blackheart series in particular has a strong following among truck owners and those who want a long-tube setup for under $1,000. While the construction may not be as refined as Kooks or ARH, the performance is close, and the price difference allows you to put that saved money toward a tuner, cold air intake, or cat-back exhaust.

Best for DIY Installation: BBK

If you are a do-it-yourselfer who wants headers that you can install in your driveway with basic tools, BBK shorty headers are the obvious choice. They are the easiest to install, the most affordable, and do not require a tune or emissions compliance concerns in most states. The power gains are modest compared to long-tube systems, but they are real and noticeable. For a daily driver that spends most of its time on the street, BBK shorties offer a satisfying upgrade without the headaches of a complex installation.

Final Recommendations

No matter which brand you choose, upgrading to aftermarket headers is one of the most effective modifications you can make to a 5.7 HEMI. The engine responds well to reduced exhaust restriction, and the sound improvement alone is worth the effort for many owners. Take the time to research fitment for your specific vehicle, check local emissions laws, and budget for a tune if you go with long-tube headers. With the right headers installed correctly, your 5.7 HEMI will reward you with stronger acceleration, better throttle response, and a more exhilarating driving experience.

For further reading on header installation and tuning, check out these resources: