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1996 4.9l Headers

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1996 4.9l Headers

Post #1 by christian » Fri Jan 18, 2019 10:53 pm

I can't seem to find headers that will fit the 1996 4.9l engines anywhere!?!? Anybody have any advice/recommendations?

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Re: 1996 4.9l Headers

Post #2 by jason832 » Fri Jan 18, 2019 11:47 pm

The stock efi manifolds are pretty good. Unless you are doing some radical engine build with custom head work, cam, etc. Anything with the factory efi shouldn't be limited by stock manifolds. Gains may be had by upgrades after the manifolds. Why the intent on headers and what is the plan for the engine?

All manifolds and headers should bolt up to any engine to my knowledge. Again I haven't seen anyone here put headers on factory efi....

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Re: 1996 4.9l Headers

Post #3 by pmuller9 » Sat Jan 19, 2019 12:08 am

The 1996 4.9 EFI has three O2 sensors on the exhaust system.
I'm not sure how you would install headers and be able to keep the O2 sensors so the EFI system would still work properly.

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Re: 1996 4.9l Headers

Post #4 by Sevensecondsuv » Sat Jan 19, 2019 9:08 am

The sensor after the cat would stay where it is. One would have to weld in bungs downstream of the collector for the upstream sensors. A 1996 ecm isn't sophisticated enough to really care much exactly how far from the engine the upstream sensors are. I did the same thing on my V10 Excursion when I put thorley Tri-Y headers on it. For some reason they thought it'd be a good idea to have the sensor only sampling 2 out of 5 tubes per side (probably so that they didn't have to include O2 sensor harness extensions) so I plugged the bungs they provided and added my own further down after the merge collector on each side. The computer didn't care, and that's one 1/2 generation newer of an ecm than a 1996 will have.

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Re: 1996 4.9l Headers

Post #5 by THE FRENCHTOWN FLYER » Mon Jan 21, 2019 9:53 am

Headers might increase the catalyst 'light-off time" - the time it takes for the exhaust gasses to heat the catalytic converters enough for them to begin to function. Because they have thinner walls and more surface area (and probably port gaskets to help them stay sealed) the light off time will invariably increase with headers. But this will not be noticed by the driver in any way. It will be our "dirty little secret". As far as I know no states check for emissions on a cold start-up engine. How could they?

The Feds do.

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Re: 1996 4.9l Headers

Post #6 by BigBlue94 » Mon Jan 21, 2019 3:38 pm

The reason you dont find them is what Pmuller stated. However, you can weld a bung into each collector, and after the cat.

Then, you get the joy of building a y pipe and exhaust. Or paying someone to do it. Was an all day job for me. Longtubes really crowd the passenger side up.

Long tube headers on an 85. Y pipe is 2.5--->3". O2 bung right after the merge. Then a magnaflow cat, borla xr1 and single 3" tailpipe.

Old vs new y-pipe. Lots of small adjustments were made here.


Not much room on an 85 bronco
Last edited by BigBlue94 on Mon Jan 21, 2019 4:11 pm, edited 1 time in total.
1985 Bronco. 309ci I6, NP435, 4.56 gears, Detroit locker and tru-trac, 4" lift, and 37" swamper tires. The 309 is 9.75:1 CR with a Schneider 140H cam, 4bbl, roller rockers, larger valves, and headers.

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Re: 1996 4.9l Headers

Post #7 by 1986F150six » Mon Jan 21, 2019 4:01 pm

Very nice work!

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