I have a 2001 5.4 250 and here recently I have been looking at replacing my leaking exhaust manifolds and from what I have been reading and looking at a lot of people who buy the replacement exhaust manifolds are having problems with them leaking a little while after putting them on and in my summit racing catalog they have a pair of headers for my truck(so they say) and they are about 200$ and come with gaskets and hardware and I was curious if anyone has had problems after they have replaced their exhaust manifolds like cracking and leaking after replacement? I know this is a issue with the jeep 4.0L and the 5.4 in my truck and I was curious to see if it would be worth it to go with headers over the manifold or if the manifolds were a better idea? here is the link to the headers Summit Racing® Truck Headers SUM-G9047 - Free Shipping on Orders Over $99 at Summit Racing

 

Use locking header fasteners and headers should be fine. They are a pain in the butt to get tight. Depending on your setup long tube are better than shorties. I had to go shorties on my 59 Chevy P/U because of the steering box. once you put them on and get them hot don't remove them because thats when they start to leak. Make sure the flanges are flat and about 3/8 inches thick. Use a good quality gasket also.

 

Those headers are only good on the light duty F250 from 97-99. The 99-04 F250/350/Excursion use different part numbers.

Edit: Unfortunately no one makes long tubes for the 5.4, only for the 6.8. Some places may be willing to make you a custom set though.

 

so I should be looking at just oem style manifolds then? there is a exhaust shop not far from me and they build custom headers but I know I would end up paying a lot for them and this is just like a farm truck not a high performance application so really not worth what little gain I may get.
any ideas on where to buy stock style exhaust manifolds from I have been looking at rockauto and the prices aren't bad but the reviews I have read from summit on the same brands has me really worried about buying a set to just have the same problem as now

 

I was told to only use Ford OEM manifolds as there are quality issues with the castings on the aftermarket ones.

Here are your other options for headers: 2002 FORD F-250 SUPER DUTY 5.4L/330 FORD MODULAR V8 Headers - Free Shipping on Orders Over $99 at Summit Racing

For what it is worth, it is usually no a cracked manifold causing the leak, but instead a blown gasket and/or broken studs. You will likely be able to re-use your manifolds but you should have them machined flat again before re-installing. I think I am going to headers on mine, but when I do I will be using SCE copper gaskets.

SCE Pro Copper Embossed Exhaust Gaskets 4046 - Free Shipping on Orders Over $99 at Summit Racing

Also, you will want to replace the studs with stainless. That will ensure this doesn't cause you problems again. You'll need 2 of these kits.


Here is a nice write up on how to do the job.

2004 F250 Broken Exhuast Manifold Stud