94-98 VS 99-04 Header guide! (Full Version)

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94-98 VS 99-04 Header guide!

  

NeoTokyo -> 94-98 VS 99-04 Header guide! (5/1/2007 11:57:22 PM)

    Hey everyone;

There has been a lot of talk on the forums about shorty headers for our sixers and there have been lots of idea's about them. I am here to show you why you need to keep your 94-98 Headers and swap those old 99-04 Logs out for a set of 94-98 headers!

First off I will show your the size differences of the two, starting with the 94-98 Headers followed by Pro's and Con's.


[image]http://i154.photobucket.com/albums/s261/mach1racer/94-98Flange.jpg[/image]
[image]http://i154.photobucket.com/albums/s261/mach1racer/94-98Collector.jpg[/image]
---------- 1994 - 1998 stock Headers ----------
Collector Size          2 1/4"
Primary Opening      1 13/16"
Primary Size             1 9/16" OD
Flange Thickness      5/16"

[image]http://i154.photobucket.com/albums/s261/mach1racer/99-04manifold.jpg[/image]
---------- 1999 - 2004 stock Manifold ---------
Collector Size           2"
Primary opening       1 9/16"
Primary Size             1 3/8" OD
Flange Thickness       5/16"

Just comparing these you can see how much larger the 94-98 Header really is. Here is a short list of Pro's and Con's.

94-98 Pro's and Con's
Pro: Superb flow
Pro: Large 2 1/4" Collector
Pro: 3-1 Header
Pro: Not prone to cracking
----------------------
Con: D-Side has factory kink in rear cylinder
Con: Firecone can have excess slag that needs to be removed
Con: O2 sensor in collector. Hard to get to.
Con: Uneven style

99-04 Pro's and Con's
Pro:  O2 not on collector
Pro:  No slag to restrict flow
----------------------
Con: Prone to Cracking
Con: Log Style
Con: Restrictive
Con: Small 2" collector



A note that I feel is very important is that I measured the exhaust ports on the 94-98 and 99-04 Heads as well. Here is what I discovered.

The 99+ splitport has an awesome intake side to the head allowing large amounts of air into the head, unfortunately Ford made the exhaust port smaller than previous years 94-98 Single ports creating a large bottle neck. Don't worry though, this can easily be ported with a flap wheel sander even while it is in the car!


Exhaust port shape doesn't mater a difference in the headers or flange.

[image]http://i154.photobucket.com/albums/s261/mach1racer/SuperHeads_3_rs.jpg[/image]
94-98 Single Port Heads (D-Shape Exhaust Ports)
Side to Side:         1 1/2"
Top to Bottom:     1 1/2"
Corner to Corner: 1 11/16"
----------------------------

[image]http://i154.photobucket.com/albums/s261/mach1racer/splitporthead.jpg[/image]
99-04 Split Port Heads (O-Shape Exhaust Ports)
Side to Side:         1 3/16"
Top to Bottom:     1 3/16"
Corner to Corner: 1 3/16"


I hope this has helped everyone out. Tell me what you guys thought.

Note: When using 94-98 Headers on a 99-04 you need to have a shop enlarge the inlet by 1/4" and bring your 94-98 Headers down for fitment. A muffler shop charged me $5 per expansion on my trucks exhaust. Its cheap and easy :)


-Eric-

  
NeoTokyo -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/1/2007 11:58:40 PM)

I took all the measurments myself, used my own pictures where applicable, its all me baby! :)

Tell me what you guys think.

MustangMike2001 -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/2/2007 12:25:23 AM)

Awesome info. Would I be able to swap my 99-04 stockers for some 94-98's? Mine are cracked might as well "upgrade".

NeoTokyo -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/2/2007 12:39:38 AM)

*UPDATE* 7/3/07
I did not have to modify the 2000 EGR tube to work with the 96' Headers that I used. It all lined up perfectly for me and cutting was not needed.
 
I have heard others say that cutting is needed though in my case it was not. Nothing was modified from the 2000 specs to fit the 96' Headers.


You certainly can, just remember in doing this swap that you need to put your O2 sensor in the header instead of the exhaust tube behind it. There is a chance it may not fit, but give it a try, if it does not fit you can buy a 96-98 one and be fine.

The EGR bung is also angled a little differently so the best way to take care of this is to go buy a Turbo hose (Rubber hose with fiberglass for high heat and pressure situations.) now cut the tube where you want (Preferably before the two hoses that come off) bridge the gap with the turbo hose and use hose clamps to screw it tightly in place.

Its that easy and cheaper than aftermarket headers :)

Here is a picture giving you two different spots that you can bridge the gap, whichever one you like. And since turbo hose comes in blue, red, black and other colors you may want it up top to show or down low to hide.

[image]http://i154.photobucket.com/albums/s261/mach1racer/EGRmod.jpg[/image]

NeoTokyo -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/2/2007 12:56:06 AM)

Sorry I used a 99+ exhaust manifold..... You get the idea :)

MustangMike2001 -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/2/2007 1:13:40 AM)

quote:

ORIGINAL: NeoTokyo

You certainly can, just remember in doing this swap that you need to put your O2 sensor in the header instead of the exhaust tube behind it. There is a chance it may not fit, but give it a try, if it does not fit you can buy a 96-98 one and be fine.



Do you mean the header or just the O2 sensor might not fit? And before you said 94-98 then here you say 96-98. Whats the difference?

NeoTokyo -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/2/2007 2:00:55 AM)

No the header will bolt up just fine.
The reason why I say 96-98 is because I am talking about the O2 sensor. 94/95 had a slightly different O2 sensor that will screw in but may not read correctly.

Dont worry though, I am almost 100% sure your stock ones will fit the 94-98 Headers.

You will have to have a shop enlarge the inlet on your stock Y-pipe by 1/4" overall though to make these work. Its cheap and easy. Bring down your 94-98 Headers as a fitment guide.

Easy stuff :)

MustangMike2001 -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/2/2007 5:29:59 AM)

Thanks for all the info! Care to elaborate on porting the 99-04 exaust ports? I love a free mod!

laserred38 -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/2/2007 11:45:43 AM)

ok nice info. is there any advantage to using the 94-98 manifolds on a splitport, other than reduced cost of aftermarket shorties? because i was just going to get some BBK ceramic shorties to replace my stock ones. i am planning to SC eventually, so i wouldn't worry about LTs until after that

SilverOnyx1 -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/2/2007 1:39:06 PM)

Great post...  thanks for the info

NeoTokyo -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/2/2007 2:47:27 PM)

The stock 94-98 Shorties aren't quite as good as true aftermarket but the difference is too close to warrant spending the money unless you go SC or use a STS turbo system (Turbo at rear of car, don't have to get special manifolds.)

The aftermarket guys usually don't say much about their 99-04 collector size because they have to leave them stock (2") so that people can use them with their stock Y-pipes. When you do decide to get a set of aftermarket headers be sure to get 94-98 shorties because they will have the 2 1/4" exhaust, you will have to change your Y-Pipe to use this larger size.

In fact anyone that has a 99-04 using 94-98 Headers must either have a shop enlarge the inlet of the Y-pipe to 2 1/4" or purchases a Y-Pipe from a 94-98. It would be cheaper to have the shop do it. I was charged $5 for each expansion on a custom exhaust setup for my truck, CHEAP!

Now I am not sure if the exhaust diameter itself shrunk in 99-04 or if it was just the inlet that changed. I can do a little more research into that.

Ultimately its still far cheaper than aftermarket headers :)

You can also have the 94-98 Ceramic coated like I had mine done. Ceramic coating the inside of them is very important too to help the exhaust flow through and to aid it scavenging. This process can become a little expensive.

Now for the main benefit of the 94-98 headers is that they are 3-1 design which promotes horsepower and torque, the primaries are almost 1/4" larger, the Collector is 1/4" larger and these don't crack :)

NeoTokyo -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/2/2007 2:54:54 PM)

Now as for porting, like I said you can purchase a flap wheel sander from Wal-Mart, Home improvment stores like Lowes or go to Grizly's website and order one.
You can also use a cartridge roll or a carbite burr.

I would stay away from carbide burrs if you are new at this, they can be very unforgiving (Personal experiance, luckily I didnt go too deep)

Start off by marking the Diameter of the porting that you would like to go to, next use either a flap sander or cartridge roll with 50 or 60 gritt paper on it and start slowly and evenly working away at the port. (Note: I put an oil soaked peice of rag into the exhuast chamber to keep aluminum from getting in there.)

After you get to your mark finish the job up with some 120 gritt paper, if you really want it to shine then you could go even finer, the 120 will leave a smooth finsih but not polished.

Now I would not go porting too much if you dont have experiance or a bad head to play with first, you dont know how close a water passage could be. I am going to call SSM today and ask him how far out is a safe port job.


-Eric-

laserred38 -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/2/2007 3:28:47 PM)

cool. well my Y-pipe is outta there. i have 2.5" divorced duals from the cats back. so obviously the midpipes are still 2.25. but when i get the headers, i was going to have new 2.5" midpipes fabbed up to use my BBK high flow cats that i have. i have the o2 sensor bungs already. if i do this, what size flange would need to be on the midpipes to meet up to the collectors of the new shorties? and then should i just get some 94-98 BBK shorties and have the inside ceramic coated? i really don't want to deal with LT's in Cali, so this would be the next best thing i think. i really just don't want to put older Ford parts on. i'd rather go aftermarket and spend a little more. but it IS good info for the guys who don't want to spend the money on aftermarket.

NeoTokyo -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/2/2007 3:55:03 PM)

When I was mentioning the Y-pipe I meant the whole thing, from cats down to the single exhaust flange going to the muffler.

If you use the 94-98 style use a 2 1/4" flange, if you use BBK's are are for 99-04 then use a 2" flange.

Call BBK and ask them about their collector to flange size, also ask them if they ceramic coat the inside of their headers, some companies do.


-Eric-

TheMichiganRA -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/4/2007 1:29:36 AM)

Soooo .... long-tubes still good?

NeoTokyo -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/4/2007 1:37:33 AM)

Oh ya, you cant beat long tubes [:D]

Its just for us smog governed guys in such states as California that this is a great idea for. Also good for the guys that dont have a lot of money, dont want to replace their cracked 99+ with the same thing or want to have to get LT x or h-pipes.

TheMichiganRA -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/6/2007 4:51:55 AM)

I'm getting long-tubes down the road. You should do an article on whether or not to get rid of your cats and putting in mils.

NeoTokyo -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/6/2007 5:06:21 PM)

Ok, that will be a couple months out but I will go ahead and make the article.

I will see if I can push my business license in the face of a few manufacturors and get some free items for the article!!!

Amanda was suppose to help me with that but I havnt seen her around forever!!!

NeoTokyo -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/12/2007 2:56:42 AM)

Here is my stock headers off of the 96' that I reconditioned, ceramic coated and baked. They came out perfect!

[image]http://i154.photobucket.com/albums/s261/mach1racer/619303-R1-14-12_015.jpg[/image]

Kikandross -> RE: Once and For All 94-98 VS 99-04 Header guide! STICKY!!! (5/14/2007 3:54:55 AM)

Question
I wanted to get the Mac aluminum headers but now I am confused.
Should i get the shorty's or long tubes?
Which year should I get 94-98 or 99-04?

I got a 02 convertible v6 with the Mac catback exhaust.

  

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