headers vs. muffler
In general, a cat back exhaust system will give you decent and easy to do performance gains.
Headers will typically give you 10-20% increase.
BUT the exhaust is a system, headers affect the mufflers etc and vice versa.
Best bet would be a complete header and exhaust system, but that might cost too much for what you want to do.
If it was me, and taking a wild guess I would probably go cat back. The really good headers cost a fair chunk of change and can be a PITA to install. A cat back is usually affordable and if you can weld you can install them yourself.
As far as towing you need low end power so you don't want an exhaust system with really big pipes and big tube headers. You just want to free up any restrictions. The muffler and tiny tail pipes are usually your biggest bottle neck as far as towing goes.
Just changing the muffler will help a little and is inexpensive, but the more parts you free up the better your performance will be.
I hope someone on this website who has done this with the 6 answers since experience is way better than generalizations.
Good Luck,
Jim Henderson
Assuming you want to tow, you will need low end power. So like I said before you will want to free theexhaust up but not with really big pipes.
I will stick with the cat back as a start. If you decide that wasn't enough, you can add headers later.
You might also post this question under the Ranger or performance forums.
Good Luck,
Jim Henderson
The weak spot is the AT/3.0 combo AND its programming. You should add a 25k GVW cooler/fan if you are towing anything heavier than 1200 pounds or if it has a large frontal area. I forget the max. sq. foot frontal area you are allowed on a Ranger, it is in your owner's manual, probably around 16-20.
I would skip headers, the oil filter is tough enough to change as it is. If you are going to spend $1,000 on that, I would suggest getting a 8.8 axle (if they do not come in the 2004 3.0L) and a ARB locker. That would be very helpful in slick situations or on steep rainy inclines.



