Recommendations for headers for a 4.6?

This past week my exhaust manifolds decided to make scene, I was leaving a car meet when I started her up and at which point a slight audible 'pop' happened on the passenger side of the engine bay, then it started making the "my exhaust manifold has a big hole now and I want everyone to know!" sound. I've repaired them a couple times now over the past couple of years, and I'm really getting sick of it, and I think an upgrade is in order. That being said would anyone have any recommendations for headers for a 4.6L? Any help would be greatly appreciated.

One other question, would deleting the secondary catalytic converters (the fat long ones) negatively impact performance or cause a Check Engine light? I think we may have discussed this before but I cannot for the life of me find the thread for it. Thanks in advance.

I had JBA shortys on mine for the longest time (10yrs+)equal length runners make for a difficult install but they are bulletproof and will outlast you. I wouldn't take the second cat out but definitely the first one and it shouldn't throw any codes.

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Thanks Killer! I'm shopping around right now and it's between the JBAs and BBKs. But $470 for the base Nautral Finish (no protection) on the JBAs is killing me considering the BBKs have a Chrome Base base finish at $350... But all things considered, how was the performance increase for your Expy?

If memory serves, and it usually still does, the aftermarket headers have fitment problems unless you go with the F150 ones. You might want to pony up for the more expensive Jba ones if they fit. What year is the 4.6? Obviously pre 05, but fitment might make the difference. We had a member here a few months back that was building his 4.6, and ended up with the F150 ones, cause the Expys didn't fit, go figure. Welding old cast iron manifolds rarely works, as you found out. My older brother tried it with his 72 Mercury 429 years back. He ended up plunking down $200.00 at the dealer for a new one. Problem went away.

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1955moose said:

If memory serves, and it usually still does, the aftermarket headers have fitment problems unless you go with the F150 ones. You might want to pony up for the more expensive Jba ones if they fit. What year is the 4.6? Obviously pre 05, but fitment might make the difference. We had a member here a few months back that was building his 4.6, and ended up with the F150 ones, cause the Expys didn't fit, go figure. Welding old cast iron manifolds rarely works, as you found out. My older brother tried it with his 72 Mercury 429 years back. He ended up plunking down $200.00 at the dealer for a new one. Problem went away.

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It's a 2000 Expedition 4.6 XLT 4x4. Another thing for me to worry about...

*Update*

So I went with the Ceramic Coated BBK Headers and they felt solid and look great (granted you really cant see them unless you look through the Wheel wells) that being said it was a ***** to pull off the manifolds (corrosion, rust and old hardware) but I eventually got them off. I also slotted in a 3" side pipe that dumps below the rear passenger side door so my floor panels quit shaking (a Big Plus).

Between the BBK Headers with my AFe Cold Air, AFe Throttle Body Spacer and the BBK Throttle Body its almost like I was able to breathe new life into my Expy and I couldn't be happier. Performance is significantly better now that she can properly Inhale and Exhale. The Sound is great, but I'm considering taking off the secondary catalytic converters to open her just a bit more, but we'll see.

All in All, I couldn't be more pleased with what I got out of installing some Headers, a new throttle body, a spacer and going from 2.5" to 3" Pipes from the Y-pipe! Thanks again to all those who helped out!