My son has a 96 F250 with the 351W engine. We have been looking at headers for this truck. All the ones we can find have the fittings for the O2 sensor and the EGR tube. What they don't have is fittings for the air injection located at the back of the engine on the exhaust manifolds. I was thinking we could fab up tubing so this will still work. Either dump it into the collector or the closest header tube. Has anyone put headers on this style of truck and how did you address the air injection? Thanks
If you're doing away with the stock cat then the whole air injection system serves no purpose so you may as well remove it. The TAB and TAD solenoids must remain electrically connected with vacuum sources plugged, and the air pump itself can remain as an idler so you don't need a shorter belt.
It does have to pass emmissions. My son has a Magnaflow cat he swaps on for that test. Rest of the time he runs a 3" Magnaflow muffler.
Your smog is the same as Cali so you will have to either locate headers with the required ports or stick with the stock manifolds. Unfortunately, unless you want to swap exhaust systems for smog, there are no workarounds.