Gibson Header Install Follow UP

Rather than continue my previous "Headers? Yes? No? thread, I am starting a new one to share the experience I have had with Gibson. After installing the first set that did not fit, Gibson sent a second set on the off chance that the first set was marked with the wrong PN or some other factory error was the reason for the fitment issues; second set was the same as the first so both sets are being returned. Kudos to Gibson as they have handled the situation in a professional manner; although the headers didn't work out, anyone considering Gibson should know that they are a stand up company.

I have attached a photo of the driver side, both sets alongside the OEM exhaust manifold; the problem is obvious. Aside from the angle and length of the header collector, the headers also made contact with the frame member above the looped header pipe.

I sent photos to JBA before ordering a set of their headers and they compared my photos with their headers and reported back that the angle of their collector was similar to the angle of the Gibson header and didn't think their headers would fit any better.

So, if anyone on this forum has successfully installed a set of headaers on a 2nd generation Expedition i.e., '03-'06 please let me know what headers were installed and if they were truly "bolt on" or some modification was required. We would have modified the OEM head pipe, very easy to do, to mate up with the Gibson collector if that had been the only issue but the frame contact prohibited that.

Makes you wonder if these companies have made too much money, and their just going all willy nilly with their tubing benders. Now you know why big companies drug test! I'll bet these headers were made for a small block Ford 5.7, and the guys just threw them in a 5.4 box. What a shame, 2 companies making the same mistake.

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Good to know. While I don't have immediate plans for headers, very are on "the list".

All is not lost. We think we may have found a set of JBA headers that will bolt on. The specific application is for '05-'06 F150 4.6L. Looking at the pictures and comparing they look like they will fit without frame contact and will hook up to the OEM head pipe. I can't say enough abou the Summit Racing tech guys who will compare these JBAs to the Gibsons, check dimensions and report back but with their "no questions" return policy, we will order and see. I am encouraged because the 2nd generation Expy years run from '02-'06 so I think these just might be the ticket; we shall see.

thanks for info; they were on my list to....still running OEM though for nearly 21 years.

Same here. Headers are on my list after 'ultimate perimeter protection'..

OK, update for anyone with a 2nd gen Expedition 4.6L that wants to install headers. After trying two sets, Gibson and JBA that were model specific that weren't even close to fitting, we tried a set of JBAs model specific to '05-'08 F-15, 4.6L, 4WD and RWD and they bolted right up, no clearance issues and the collector connected right up to the OEM head pipes.

If you look at most of the headers that are model specific for 2nd gen Expeditions, they all look the same, like the Gibsons (see previous post) with big looping pipes from the rear cylinders and you wonder how they will fit that application and, wait for it, they won't.

The JBA PN is JBA-1687S; they will bolt right up.

Unbelievable, you had to do their job. What's amazing, is the same basic vehicle, in a pickup version was the ticket. You need to let both companies know, so that hopefully they'll relabel the pickup ones to the Expedition application. Good job though.

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Good info! Forgot that they also had 4.6l's in Expeditions. I thought all had the 5.4L.

Expeditions had 4.6 till 04.

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