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The Ford Mustang is one of the most recognizable cars on the road, much thanks to its sleek silhouette, thrilling performance, and aggressive exhaust note. Still, while already tuned for performance, Mustangs can benefit from aftermarket modifications, such as exhaust headers.
Mustang headers replace the stock exhaust manifold and improve engine efficiency by optimizing the expulsion of combustion gas. This results in noticeable performance gains and a more pronounced audible rumble.
However, there are multiple types of headers with numerous coating options to cater to different performance needs. There are also a plethora of diameters and lengths to consider to ensure proper fitment and optimal power gains. Thankfully, JEGS is here with a detailed Mustang exhaust header guide.
We’ll start by reviewing the various header components, then explore header sizes and coatings. Finally, we’ll share some of the best headers options for each Mustang model, from classic to current, with or without engine swaps.
Let’s get started.
Mustang Header Components
To fully understand the impact of exhaust headers on a Mustang's performance, it's important to have at least a basic idea of the different header components and how they work.
Here are the main components of an aftermarket header setup:
- Header Flanges: These are the connection points that attach the header to the engine. Made from thick metal, they ensure a secure and leak-free bond with the cylinder head.
- Primary Tubes: Individual pipes extending from each cylinder, these tubes help direct exhaust gas away from the engine. Their design and length can vary to suit different performance needs.
- Collector: This part is where the primary tubes converge, where the exhaust flow from each cylinder combines into one stream, leading to the rest of the exhaust system.
- Gaskets: Positioned between the header flanges and the engine, gaskets provide a seal to prevent exhaust leaks, ensuring optimal performance and emissions control.
- Oxygen Sensor Bungs: Modern headers often include these for the oxygen sensors, necessary for the engine's fuel management system and emissions control.
- Hardware and Accessories: This includes bolts, clamps, and sometimes heat shields or wraps, which are needed for installing and protecting the headers.
Different Types of Mustang Headers
Shorty headers are a popular choice for their ease of installation and compatibility with stock exhaust systems. As their name implies, these are shorter than other Mustang header types, fitting more easily into the engine bay.
Shorty headers are typically a drop-in replacement for factory exhaust manifolds, making them an ideal option for Mustang owners looking for a straightforward upgrade that boosts performance without the need for extensive modifications.
This direct replacement aspect simplifies the installation process, making them a practical choice for those who want to enhance their Mustang's performance with minimal hassle.
Long Tube Headers
Long tube headers offer more significant improvements, making them a favorite among Mustang performance enthusiasts. These feature longer primary tubes vs shorties for better exhaust flow and reduced back pressure, resulting in noticeable horsepower gains and better engine efficiency.
Long tube headers typically run down and under the firewall and floorboards, which contributes to their ability to provide more high-end horsepower compared to shorty headers. Shorty headers offer more low-end torque and are preferable for street performance due to their design and placement.
Just note that long tube headers aren’t typically street legal as they move the CATS further back from the exhaust manifold, likely violating emissions standards. As a result, long tube headers are best for performance activities like track racing or sanctioned events, where the focus is on maximizing power and efficiency within regulated environments.
Tri-Y Headers
Tri-Y headers, an option in 1965-1970 Mustangs, are designed with a unique layout where two pairs of cylinders merge into two tubes, which then merge into one. This design optimizes exhaust flow and scavenging at different RPM ranges, offering a balance between low-end torque and high-end power.
Tri-Y headers are a great option for classic Mustang drivers looking for a versatile performance upgrade suitable for both street and track use.
Equal Length Headers
Equal Length Headers in Mustangs ensure uniform exhaust flow, enhancing engine performance. This design maintains consistent exhaust gas lengths, leading to smoother flow and improved power.
These headers are known for making the exhaust note louder and more aggressive. Ideal for those seeking performance upgrades, equal length headers increase horsepower and torque by allowing unrestricted exhaust flow. They're a great option for Mustang enthusiasts aiming for a balanced upgrade in performance and sound quality.
Types of Exhaust Header Coatings
To withstand the high temperatures generated by a car’s exhaust (1,300-1,500 degrees Fahrenheit), different types of Mustang header coatings are used.
Here are the most common coatings you’ll come across when shopping for Mustang GT headers, Pony headers, Boss 302, etc.:
- High-Temperature Paint: This coating is affordable and effective for handling the high heat of performance exhausts. It helps in preventing rust and can sustain the extreme temperatures that performance vehicles like Mustangs generate.
- Stainless Steel: Known for its durability and resistance to corrosion, stainless steel coating maintains its appearance even under high temperatures. It's a popular choice for those prioritizing longevity and aesthetics.
- Nickel-Chrome Plating: Offering a distinctive mirror-like finish, this coating adds a flashy look to Mustang headers. While it provides good resistance to corrosion, it might be less durable under the highest temperatures.
- Ceramic Coating: A premium option, ceramic coating greatly reduces heat and offers fantastic corrosion resistance. Ideal for high-performance Mustangs, ceramic ensures longevity and efficiency in managing exhaust heat.
Mustang Header Diameters and Lengths
When shopping for Mustang headers, it’s important to keep their diameter and length in mind.
The diameter of the header tubes affects exhaust gas velocity and engine back pressure. Larger diameters usually allow for more flow, beneficial for high horsepower engines, but can reduce low-end torque. As for smaller diameters, these can enhance torque at lower RPMs.
As for the length of the headers, shorter tubes typically improve low to mid-range torque, making them suitable for street driving and balanced performance. Longer tubes, often found in racing applications, favor high RPM performance.
It’s important for Mustang owners to choose headers with diameters and lengths that match their driving style and performance goals. Whether it's a daily driver, a weekend track car, or a full-blown race Mustang, the right combination of diameter and length can greatly influence overall engine performance.
Getting New Mustang Headers With or Without Engine Swap
Whether you’re rocking a classic Mustang from the 60s or 70s or a modern Mustang with an EcoBoost engine, there are plenty of header options to suit your needs.
Below, we’ll review the different Mustang variants through the years and explore the best header options to consider:
- Classic Mustang: Classic Mustang (1964 ½-1973) header options include Tri-Y, Long Tube, and Shorty options. Tri-Y headers boost torque and offer better clearance, while long tube headers favor high RPM horsepower gains but reduce clearance. Shorties are great for throttle response and wider torque range. Specific headers are needed for engine swaps or dual exhaust conversions.
- Fox Body Mustang: Next up is the Fox Body Mustang (1979-1993), where shorty headers are a common choice due to their easy fit and solid power gains. Long tube headers, while offering more performance benefits, might not be emissions-compliant, unlike shorties, which are usually fine across all states. Equal length headers are also a great choice for drivers wanting a balanced upgrade in their Mustang's performance and acoustic quality.
- SN95 Mustang: For SN95 Mustangs (1994-2004), long tube headers are a great choice to enhance their already impressive sound and provide unrestricted airflow, boosting performance. Shorty headers are also beneficial, offering improved throttle response and fuel efficiency, making them a versatile option for these models.
- S197 Mustang: For S197 Mustangs (2005-2014), the earlier models (2005-2010) with a 4.6L V8 benefit greatly from header upgrades. Both long tube and shorty headers can enhance exhaust flow for improved horsepower and torque. This upgrade bridges the performance gap between the 4.6L V8 and the 5.0L Coyote V8 found in the 2011-2014 models.
- S550 Mustang: For S550 Mustangs (2015+), long tube headers can address the integrated catalytic converter on the driver’s side manifold, offering added horsepower and torque. Some long tube headers may require an adapter mid-pipe. Alternatively, short tube headers offer power gains and are easier to install but may require some modifications to reattach the factory CAT.
When browsing for headers for a Mustang with a swapped engine, it's important to factor in the specific requirements of the new engine. Engine swaps often change the exhaust system's layout and performance characteristics, requiring headers that are compatible with the new engine's design and exhaust pattern.
For instance, an LS swap in a Fox-Body Mustang would require headers specifically designed for the LS engine's configuration. Similarly, for later models like the SN95 or S550, ensure that the headers chosen align with the physical dimensions and exhaust flow requirements of the swapped engine for optimal performance.
JEGS: For All Your Automotive Needs
Congratulations, you should now have all the needed information to confidently choose the best Mustang headers for your goals. For all your automotive needs, consider JEGS, a leading supplier of performance auto parts, including aftermarket headers.
Complete your order online and have your products sent straight to your door. Still have questions? Contact our team today.
