2005 Nissan Frontier

In an article that inspired our Fantastic Four series, we showed readers how a Nissan Titan can become a totally different beast after a couple of days of wrenching. This time around, Nissan's mid-sized offering will be the lucky recipient, as a 2WD V-6 Frontier will get Calmini's newest 5-inch lift, JBA's latest exhaust system, an Advanced Flow Engineering (AFE) intake, BFGoodrich tires, and American Racing wheels. A few years ago, the Frontier was practically an also-ran as far as compact pickups went, but since the redesigned '05 model hit the streets with its increased size and bigger V-6 engine, aftermarket companies have given it the attention it deserves. Calmini has been providing lift kits for Nissan's mini trucks for years, but the addition of the 4.0L VQ40DE engine allowed the Frontier to power the extra mass of larger tires without a compromise. Read along as the Frontier began at JBA's Performance Center in San Diego, where its VQ engine got the breathing it needed. Then, the Frontier moved on to Wheel and Tire Connection in Lake Forest, California, where it was given a new stance for the final transformation.

As a factory-stock truck, the charcoal-gray Frontier was in need of some help.	To begin the install, Jarrod put the truck on the lift at JBA's Performance Center in San Diego, where the factory exhaust manifold was unbolted from the midpipe.	Jarrod unbolted the exhaust from its hangers and removed the midpipe to provide clearance before unbolting the manifolds. This took a lot of maneuvering, as bolts were removed through the wheelwell and from below the truck.
After the original gaskets were cleaned, a bead of Permatex Ultra Copper went on around each port.	The original equipment didn't look bad, but you can imagine how exhaust reversion was possible. The new piece provides an almost equal-length 3-into-1 and uses a titanium ceramic coating over stainless steel to withstand high temperatures, while it insulates the engine compartment from heat.	With the new headers bolted in place, the midpipe and O2 sensor could be reinstalled.
Jarrod sprayed the hangers with penetrating lube and removed the remaining exhaust in one piece.	Each piece was clamped into place after the U-bolts were given some anti-sieze compound to prevent galling. The JBA kit even had a stud welded on for the factory ground strap.	Each piece was clamped into place after the U-bolts were given some anti-sieze compound to prevent galling. The JBA kit even had a stud welded on for the factory ground strap.