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99 F350 4WD CC 4.30LSD tow and custom camper package XL model. Has 70,000 miles, well maintained, I am the second owner. Rust starting on the bottom drivers door and it has spit a spark plug with a Heli-coil repair. I will soon need to replace the exhaust as I can almost poke my finger thru the muffler and I have 1 broken exhaust stud. Here's the question: Is it worth throwing $2,000+ dollars at for a Bank$ or Thorley$ exhaust system or do I throw cheapy Ebay stuff on it? Or just throw a muffler on it? The truck is set up to haul my camper and boat for family outings and does a great job. I do not want to have any problems on the road but don't want to throw good money into the pit of no return if you know what I mean.
If the engine is still in good shape and you plan to own it long enough to feel you would get your moneys worth out of it then go for it. If you think it will die in the next few years then probrably not. In this day and age you have to plan on driving it to get your money out of it and not count on resale.
It is in good condition, no leaks, complete service records and I do not feel like setting up another truck to do the job it serves. Seems like alot of money, almost 20% of purchase price, to throw at it. New trucks are not cheap though either....
In the end you'll have to decide how much you're willing to spend. If I own a truck I usually own it till it turns to powder in my driveway, and when it's time to money in it I try do it so I don't have to fix the same thing for as long as possible. Go cheap and you'll be right back here again in a couple of years. So it goes back to the question of how long to you think you'll own the truck? How many times do you want to put an exhaust system on it? How much can you really afford to spend. Mostly though which solution will cause you to lose sleep? Spending alot or wondering how soon you'll be asking this same question again? Good Luck!
You can get the Thorley headers and y-pipe for under a grand shipped to your door. The headers come with a new y-pipe and replace everything from the manifolds to the triangular flange in front of the cat. If the exhaust tubing is good and only the muffler is shot, just replace the muffler. As for the plug problem there are permanent fixes that don't require pulling the head as you know. At 70k miles the engine is just getting broke in. I would spend some $$$ on it and keep it if it does the job and your happy with the truck. To buy another new or even used truck to replace it you'll take a hit when selling the 99' and lay a decent chunk of cash down for the new vehcle.
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