Broken Header , Pass side .... what options ?

[Lemondrop]

Ok,
This is the 5.0L's right side header , factory 1996 . It had been leaking for some time off and on , and I thought it was the gasket . Today I went to change the gasket and the front 2 ports of the header fell loose from the back half so obviously it's broken in half .
Now , I personally think these factory headers suck the big one . I know there are aftermarket headers out there in thr $600 range but Im not after performance , just a kid-getter .

What Im after is if the cast iron manifolds from the later engines can be used , direct bolt on for this broken header ?
I don't know when they started using the EGR tube from the manifold but mine does not have it , the EGR is all in the intake manifold .
Id imagine the hole could be plugged up but that won't matter if the manifold won't attach to the Y pipe without modding .
If I have to buy a used header I guess that's what I will do because Im not spending $450 on ONE pass side header , Id buy both new aftermarket ones .
Thanks .

 

[section525]

You can put any 5.0L Explorer exhaust manifolds on your '96. I have the EGR bung on the headers on my '96 and I just had it plugged. These stock manifolds are on eBay all the time (if you didn't know).

 

[Lemondrop]

The only ones I saw on ebay were the 98 and up versions . Your saying they will bolt in directly to my Y pipe without modifying it ?

 

[section525]

Yes. They probably only say '98 and Up because of the EGR.

 

[Lemondrop]

Bought a header from the local auto parts store for $197 plus tax . Problem is it has a port for the EGR I need to plug . Anybody know what size the cap for it is and if you used pipe thread , NFOS , JIC , Etc ?

Im sure I could rig something or maybe even nuke the hole shut with my mig if needed .

 

[Bill MacLeod]

Ifffff, the bung on the Explorer header is the same thread as the 94/95 Mustang headers, then there if a fellow in Florida that sells caps.

Go to www.wazeepulleys.com Check in the 94/95 Mustang parts.

 

[rcpasq]

Torque Monster Headers...

The '96-'97 exhaust manifolds a very prown to cracking. They fit the original GT40 heads in '96, very early '97 and GT40-P heads in '97. Ford utilized cast iron manifolds in '98 through the end of production in 2001. They will work on the earlier heads and they do breath a hair better, and I mean a HAIR better. To plug the EGR connector hole you will need a plug size of M22x1.50 (metric).

A set of Torque Monster headers would fix those manifolds. They can be ordered without the EGR connection on the right (passenger) side, the smooth tubes model. At the same time you would end up with about 20 extra hp and 35 ft. lbs. of extra torque. They are direct bolt-ins and connect to your stock exhaust. Only $589 to your door. See them under the Group Purchases thread.

If you have any other questions, send me an email at "rcpasq@yahoo.com"

All the Best,

Bob Pasquale
Tech Performance & Engineering
Torque Monster Headers
P.O. Box 22088
San Diego, CA 92192

 

[enyego]

how come the exhaust manifolds didn't change with the changeover to GT40-P heads?

 

[section525]

They did. They went from stamped steel to cast.

 

[BeauJ]

You can pick up a set off eBay with ease. I've seen them go for 10 bucks on there before

 

[enyego]

can the be improved in any way? I guess I thought the P-heads were the reason most guys can't use headers(ex. Torque Monster, FMS), but the same must be true for us internal egr guys? I suppose it's a clearance issue?

 

[enyego]

what style of header do the lightnings have?

 

[nightryder]

i just had to replace the passenger side on my 97 5.0. Was a pain, but i got it done pretty easily. I do have the egr hose but it came with a cap for the nipple on the exaust manifold. I got the part from https://www.rockauto.com/dbphp/mak,FORD,1996,EXPLORER,1119697,5.0L+302cid+V8+MFI+(P) for about 175.00. You could try it, good luck!