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2002 F250 SD Ext Cab 4x4 V10
I have had an exhaust leak for a little while on the one side right at the exhaust manifold. The guy that does my inspections said I should replace it due to it possibly being warped (Its missing quite a few studs and has for about 2 yrs) But when I saw that they cost over $500 from Ed, I started thinking of headers. But I was wondering how everyone else likes their headers and what brand are you running? My guy said there is a possibility of hesitation off the start with headers. Have any of you experienced this at all?
As far as warpage, you could get them machined for probably less than $100. Now to brand of headers many are using Hedman,Doug Thorley(cashy),and Gibson(also cashy). Some have tried the less expensive e-bay headers(not sure exactly which ones) and have had good and bad luck. Probably doesn't help much.
Some say that the "shorties" don't offer much below 3000rpm and can have an annoying tinny sound,which is usually helped with header wrapping cloth. More will chime in. You can do an advanced search in the search link,looking in the V10 forum and you will find days of reading material...
my vote is for the Banks headers, but new they are pricey!! also there are headman's, gibson, and doug thorley. i think JBL made some shorties at one point in time, not sure if they still do. Ford Racing also has some shorty headers for the 10ers too. there was some thorley's on ebay at one point in time for around 600 or a little more.
if your looking for a cheap quick replacement, you can find ebay headers for $150-$175, but remember that you get what you pay for. some have had no issues what so ever with theirs, and others have noticed cracking over long term use, and i've witnessed them crack and break after one mud ride.
I have the Gibson's, Quality is great, install is a little difficult because of the bends in the tubes tend to get tin the way. Performance wise, I see no difference under 2500 rpm's. No loss or gain. But from 2500 and above the motor does rev faster. Butt dyno says there is some extra power. As mentioned above I do have a little nbit a tinny noise, not horrible but it is there. I got mine used from a friend. I don't think they are worth it if paying full price. IMHO
I went with Doug Thorley headers on my truck about 26k miles ago and the truck works and runs great. Thorley headers have thicker 14 ga. tubes and have good gains but they are more expensive and have become harder to find. I would recommend going with a custom tune with header though. If you don't want to go to headers I have my old manifolds that I'd part with. They have 20k miles on them and are flat and not warped.