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I have a 2003 Ford Excursion that has developed a leak from the exhaust manifold from, you guessed it, rusted studs/bolts. I have located stainless steel headers (~$150) and an aluminum Y-pipe ($80) on Ebay. There are other topics relating to these individually, but none of which discuss whether or not adding these modifications would impact my state of IL required smog tests. I know JBA has headers that are listed smog/CARB certified but I have not seen other brands with this certification.
Long story short, will adding these modification result in my truck failing the smog test (it currently passes). I also plan on adding a flowmaster muffler as well but I know that won't impact the smog test.
As long as you keep some kind of CAT in there you should be fine. Mine has custom exhaust (duals w/crossover, aftermarkets cats, flowmasters etc) and I didn't have an issue. All they do is walk around with a mirror looking for who knows what - I guess just to see if you have a converter? Keep in mind all state smog inspections have there own differences so your results might vary.
Where did you get your headers? Mine is due to have the manifold bolts replaced and I might go the header route while I have it apart as long as they bolt right back in place and I don't have to have the exhaust reworked.
I bought a set of ebay stainless headers and the passenger side would not fit without notching the frame. Luckily they took them back and refunded my money. Are you in a CARB state? If so, you'll need CARB numbers on each item to ensure you pass.
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