I have a 97 Mountaineer (Explorer-eer) V8 with an exhaust leak. I was quoted over $800 by the dealer to replace the manifold. There's no way I'm going to do that - especially when the lady from the dealership called me and said, "I'm not sure how much you want to put into this vehicle..." I was thinking about putting headers on the thing anyway but I have some questions and I'm hoping that someone here can help me out before I decide what to do.

My questions are....

1. I have heard that Ford (Motorsports?) makes some OEM headers for my vehicle. Is this true, and if so is there some online source that I can use to purchase them at a good price? (I'm hoping for a direct link to the right part I need OR an exact part number if possible.)

2. If, in fact, Ford does make a set of headers for my vehicle do they have all of the appropriate connections, etc. to replace the existing manifolds? (I haven't looked yet but I'm assuming that there are some kind of emissions and/or performance related sensor connections on the existing manifolds.)

3. If #1 and #2 are true is it possible that adding headers will negatively impact my performance? (Other than the headers the vehicle will still be 'stock'.)

Thanks in advance for any and all help that you can provide!

 

Welcome to FTE Matt!!!

Unfortunately, I am going to be the bearer of bad news - you cannot get the Explorer headers anymore. Ford did make them, but discontinued a few years ago. You could buy them up to about a year ago, then everyone ran out.

I do know of someone who is having a company make some custom headers for Explorers, but they will run about $800 to $900 a set... If you are interested, let me know...

 

I don't think I'd be interested at that price.

I found this while doing a little searching:

M-9430-E53 97 Ford Explorer V8 Ceramic Headers

Would this be the right part number?

 

That WAS the part number. The Ceramics have not been available for some time, and the stainless (M-9430-E50) are not longer available either. They were both made for 96 and early 97 model Explorer 5.0's. You would have to modify them to fit a later 97 and up 5.0 - that is if you happen to luck up and find a dealer with a set just sitting on a shelf somewhere...

 

Is there a way to determine whether I have a 'later' or 'earlier' 97? (I would guess that the stainless ones are preferred to the ceramic ones. On the incredibly slim chance that I do find a pair sitting on the shelf somewhere would the ceramic ones be OK?)

 

Most would prefer the ceramics. I have the stainless ones, and had them powder coated. But if you ever find some new or used, stainless or ceramic - I suggest buying them right then. I know over about 150 different people looking for them (probably more).

There were 2 different styles of 5.0's used in Explorers. The largest difference was the heads and the EGR setup.

96 and early 97 (before around July or September 97 manf date) came with regular GT-40 heads, and had an internal EGR system. The EGR valve was mounted on the intake elbow between the upper intake and throttle body.

Late 97 and on had GT-40P heads, and had external EGR setups.

The easiest way to tell is look at the manifold on the passenger's side of the engine and see if there is a tube running from it to the EGR valve. If it does, then you have a late model 5.0. If there is not a tube welded onto the manifold, then you have the early setup.

Any Mustang header would fit the engine, but you run into a hard time getting your exhaust pipe bent corretly to line up to the headers. Offroad truck headers won't fit because they 1)hang too low, and 2) will not fit in the allotted space for an Explorer.

 

Cobra XP,
I have a 97 Mountaineer built early Febuary 97 that has the later type engine in it with the external EGR. I could be mistaken but I believe the changover was the first or second week of Febuary. I know my build date calls for the earlier parts when ordering or buying them but they never matched and I would have to swap for the later style. If I have the later type headers and EGR would I also have the later type heads? I got a new exhaust header last fall for replacement. This is 302 V8 AWD.
Greg Sanders

 

Tennessee -

I have not seen an Explorer or Mountaineer that came with the external EGR and had GT-40P heads. I am not saying you don't have them, but it is highly doubtfull. There are two ways to tell the difference in the heads:

• If the spark plugs are facing more straight, they are regular GT-40 heads. If they point towards the firewall, they are the P heads.
• Look at the side corner of the heads closest to the radiator. The P heads will be stamped with a GTP, and the regular GT-40 are stamped GT.

Look at your passenger side manifold. If you see the steel tube welded to the manifold and running to the EGR valve, then you have GT-40P heads.

 

Would you mind telling where you got the replacement headers?

 

CobraXP and MattBrink,
I have what looks like a small EGR valve at the rear passenger side of the 302. There is a blue steel pipe that runs from this to the exhust header but it has a nut and fitting to connect to the header, not welded on as you refer to. I haven't been able to find the GT 40 stamped on the heads as I looked quickly. This could still be the earlier set-up as I'm not sure.
The header was replaced by a Ford Truck Dealer in Nashville. This was done in November. I have had a lot of problems with this vehicle and Ford added a 6 year 100,000 mile warranty on for me. Some of these vehicles with the old type headers [if this wasn't changed until summer of 97] should still be available as Ford would have extended warranties still in effect on these vehicles and would have to able to fix or repair them some way. Mine was a new header as it was "clean and bright" when installed. No way it could have been a repaired one and looked like it did.
Greg Sanders

 

Matt - what he has are stock manifolds I believe, not FMS headers (the part numbers we discussed).

Tennessee - if you have a tube running from the EGR to the exhaust manifolds, you have the late model setup with the external EGR and GT-40P heads. I thought they were welded, but if they have a nut - thats even better. When they replaced your manifold, they replaced it with a new stock manifold. What Matt is looking for is a set of aftermarket headers for performance. Neither Motorsports nor any other company make a set of aftermarket headers anymore for a 302 in an Explorer. Yes, you can get stock manifolds all day long, but not headers, unless you do like I stated earlier and use Mustang headers and figure out a way to get the pipes to match and fit in the allotted space.


I do not have any pics that are great details, but I hope these will help:

This is a pic of a 97+ intake with intake elbow and DPFE sensor mounted on it. Notice the shape of the intake elbow - it is not perfectly square. It also has a port fabbed onto it for the EGR to bolt to (the EGR is unbolted in the pic). Notice the position of the DPFE sensor. Early models do not have a DPFE sensor mounted to the upper intake.





This is a pic of the early model intake elbow. Notice how the top of it is flat, and is not rounded as in the one above. You cannot see the EGR in this pic, but it mounted flush against the back of the intake elbow.



I hope this helps... I can get better pics if needed...

 

What I have are the stock ones. Originally Ford referred to these as shorty headers I believe. I never knew Ford or anyone else made any different headers for this set up as I have looked with no luck. Mine is definitely the later type engine as I have replaced the DPFE in this position on the manifold. My build date was 2-7-97.
Greg Sanders

 

Ok, so getting the performance headers is out of the question. How about getting a replacement for the existing cracked passenger-side manifold then? Can it be one at a reasonable price?

 

Matt,

Check your PM...

 

I just got done changing the right exhaust manifold on my 97 Mountaineers. Can't believe how fairly simple it was. Wanted to post the process here.

The exhaust system was making a louder and louder sound over the course of the last year. I finally got a piece of heater hose out to listen through to pinpoint the problem. The manifold leak was pretty much right in the middle of the pipe, under a heat shield cover. So, time to order parts and read up on the procedures.

I got an OEM 97 manifold that needed a cap to cover the EGR that was routed into the manifold later in 97, mine didn't have that pipe. Also, a new gasket is needed. Cost of parts was around $360.

Ready for R&R. Jack up & remover right front tire. Remove the black plastic inner fender shield. Soak the manifold and Y pipe connection bolts with PB Blaster. Soak, soak, and soak some more. I start soaking at 4:00 PM on Tuesday and repeated every couple of hours. All ten bolts and less that one can was used.

Noon today I finally decided to give it a go. Started on the flange connection first and those bolt came off with ease. I was so shocked I tried the bolts to the engine and each one came off with little effort. The manifold was actually cracked totally in half. The gasket came right off due to the soaking.

The new manifold can be slid in from the right hand side (looking at the opening), without removing anything else. Bolted it back up and I'm driving much more quietly. This is a job anyone can do with a nice set of tools and time for soaking.