I've searched the topic but still can't decide what to do. I just bought a '95 F250 460/5spd with 179K on it. The manifolds are leaking profusely and I need to get it fixed to pass good ol' Missouri inspection and get plates. After reading here I chickened-out and had a shop loosen all of the manifold bolts for me so that's done and none broke off. Also had them do a compression ck and all are 7 are around 170psi and 1 at 150psi.

I bought this truck as a 3rd vehicle to use mostly around my farm, and occasional towing of my Jeeps (3-4 times/year).

Anyway now I can't decide between messing with the existing manifolds, a set of Hedman headers/y pipe/existing exhaust, or the better L&L headers with either existing exhaust (if even possible) or duals all the way out. Obviously I love the last choice but dunno that I want to spend that much right now as I'd have to do not only pipe/mufflers but also 2 cats to get it to pass inspection and fear I'll be at $1000 in no time. Are the L&L's worth the extra $150 (+ dual setup if factory will not work) for what I'm using this truck for?

thanks!
Brandon

 

I had the exact same problem that you do. I had my manifold gaskets replaced because i thought that they were leaking, but it turns out the manifolds were warped. So i spent $275 to fix them (some bolts broke off in the head), and the manifolds still leaked due to being warped. I was pissed. So i bought a set of Hedman Headers for $159 from summit (HED-89280) and had a custom dual exhaust put on. Luckily my truck is non-catalyst, so I did not have to worry about catalytic converters which saved money. However it is now without the AIR tubes in the stock manifolds, but I don't give a **** because I keep it mileage exempt. The exhaust is all custom bent 2.5" pipe exiting behind the rear wheels, and it cost $450 for all the parts, labor, and header installation. I do not think it was a bad price, and it was worth it. I went with glasspacks to save some money, and maybe later on ill change it is i get bored with it who knows. I would bet you have the same problem as I did with the warped/cracked manifolds, so go with headers. They can probably hook it back up to your stock exhaust if you wish to do that also. Hope this helps, Jesse

 

I had the Heddman headers on my EFI 460 and didn't care for them. They are mild-steel prone to rusting out and cracking from the high exhaust temps of a loaded big block. They were not very well made-- poor welds (including a leaks in the collector from incomplete welds) and their idea of "sealing" is to grind flat a sloppy raised weld-bead around each exhaust port. I replaced each side once due to failure. One header actually rusted from the inside out (and I live in AZ where it never snows and rains like 20 days a year!) When I put my new 460 in I decided to go with the Banks TorqTube Tri-Y headers. They are spendy (around $800) but you get what you pay for: 5/8" flange that is leak-free with NO EXHAUST GASKET, thick 409 stainless construction, all the hardware including a starter heat shield came with them, will bolt right up to the existing cat. I had mine JetHot coated. After 2 years I am still very pleased. No exhaust manifold leaks, no blown gaskets (since there are none) and never had to retorque a loose header bolt. These will last the rest of my life.

The rest of the exhaust is 2.5" from the collectors to a Flowmaster Y pipe to sinlge 3.5" exhaust all the way out. Muffler is a stock '04 6.0L PSD stainless unit.

 

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