I have an 02 SD F250 5.4 scab and I have replaced my exhaust manifolds twice 3 yrs with cheap Dormans and they look like they've been on for 10 yrs and extremely rusty and are leaking again and sounds like crap.

What are the best exhaust manifolds/headers to get for the money?? Its a work truck and I'm not trying to spend 5-700 bucks on headers. I'm tired of replacing them every year after winter. I have a good buddy of mine that will help me do them. Can you please give me some options. Thank you and have a good day.

 

The original stock manifolds I have found. Once they heat cycle and warp they don't continue to warp. I just have them machined flat and reinstall.

 

2003 F-250 SD 4X4. 5.4 I put the $$ out for the JBA catforward headers, and the SPD Y-pipe connector. I added a flex pipe BEFORE the cat so they won't crack after learning the hard way. Got rid of the studs and went to bolts.It runs very well now, and I haven't had an issue yet. Good luck.

 

Stock set for my 2008 were $400. That includes all the bolts and studs. I put a few coats of POR15 exhaust manifold coating on them. Replacement FORD set on there only lasted a few years

-matt

 

Just got this setup on eBay today for a little under $170, free shipping. haven't arrived yet, but I'll be one happy camper if they are what they're supposed to be. I believe it said for '97 (or '99?) to '03 (or '04?) 5.4L F-150's only, but there were similar setups at similar prices for newer 150's, so there might be some for 250's too. ...definitely not JBA's, but at least the seller was in the USA, shipping takes a week or less, and... stainless longtubes w/EGR plus cats for well under $200!!

 

...sorry for pulling up an old thread, but this is something I'm interested in, and I thought others might be interested in the header+cats package I found. will post installation notes & pics as the project unfolds

 

I'd be interested in knowing how your project turned out, I'm looking for a set of exhaust manifolds also, I'd consider headers.

 

they've arrived!!
good news: all tubing passed the magnet test - the primaries, collectors, and "cats" are T304, as advertised.
bad news: the flanges, o2 bungs, and EGR bung did NOT pass the magnet test. my best guess is that the flanges are regular carbon steel, with some kind of plating - maybe nickel. don't seem shiny enough to be chrome, and too shiny for zinc. surfaces are micro-rough (hard to explain!), like maybe sandblasted & then a super-thin plating. should help hold gaskets.
not sure about the bungs - maybe 409 stainless.
good/bad news: the "cats" are not cats, just perforated pipe straight thru, inside a larger diameter chamber. good, because probably more power, but bad because it makes o2 sensor setup a little more complicated...
for "political reasons", I can't do the installation for another couple weeks - have to convert dining room to baby play room & finish some other home improvements before daddy can play!!
but I'll start a new thread with details & pics when I do it 😀

 

Did you post a new thread? If so, please link