I can tell you that stock headers are ****TY. I KNOW i have more power in here( although she'l scare you already), but I quit shaking and need headers. I have a few experienced answers and questions.
The ticking noise is probably your egrtube. Try a new header gasket( 94-95 mustang exhaust manifold gasket, stock form from fel pro). if the ticking is still there, verify it is the egr side ticking, new egr tube at ford is less than 60.00. however I had to make my own,( aftermarket intake manifold, phenolic 1" spacer, 95 mustang throttlebody adapter all screw up your alignment of fittings) still not perfected, but every temporary fix i do eliminates the ticking completely
question to all header designers,, I am anxiuosly awaiting a set of better flowing tubes, but what are you doing about the location of exhaust pipe on 4x4 or AWD driver side. There is only 1 place for it to get out of engine compartment. Ford even ball peened the oil pan to death to make the "valley" ,,,hell glorified dent, to accomidate the tube. What about the steering shaft? What will this do to the heat ie ac blwer side? I have a set of BEAUTIFIL stainless ceramic mustang headers (94-95) the tubes are larger, and guys they almost fit. small alterations( steering u joint, moving 1 tube,, 2 piece desing, change the angle of collector slightly,, they might bolt in.. I tried till i cried to get these to work, but short if hit them with a hammer, I'm now equipment challenged. Have you tied these for a starting point?
please let me know troll, how you are coming along on this. I am waiting on ya, listening to no more B.S. ( the headers came from a dealer whose rep said he watched them go into an explorer of his friends, I called him sobbing,, he no longer.....you know