GT40P engine in Bronco - GT40P heads AND GT40P HEADERS that WORK - Ford Bronco Forum
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post #1 of 43 (permalink) Old 05-10-2006, 06:01 AM Thread Starter
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Exclamation GT40P engine in Bronco - GT40P heads AND GT40P HEADERS that WORK

Well,

I know there are a ton of threads about "headers" and of course tons of tech related articles as well. Most of those threads or articles touch base on how certain aftermarket headers will or will not work with the 5.0 or 5.8 engine in a Bronco (or F-Series trucks). We all know there are the Summit Racing "cheapy" headers that do work, but require Y-pipe mods or tweaks... then there are the BBK, MAC, JBA, Gibson headers and so forth - but again, they all are addressed most of the time to the standard E7 5.0 or 5.8 heads.

I blew up the original 5.0 in my 94 Bronco last December and have finally gotten around to working on the rebuild. The old engine was trashed and there was no possible way it could be rebuilt at all (another thread exists on that).

So, I had purchased a complete Explorer 5.0 long block to use as my base rebuild, because of the fact that it's a "GT40" engine. The engine I chose is actually a GT40P engine, which means it has the infamous GT40P heads on it. If those of you out there know Mustangs or 5.0's in general, you all know that the GT40P heads require different or specific "GT40P" headers.

Now let me note for the record before I go on further - I read MANY threads on MANY different forums both F-Series trucks, Broncos & Mustangs - and many have stated that the Ford stock tubular 5.0 headers would work, many have stated the standard BBK headers would work and so forth.

I can attest by actually TRYING out the following headers on a GT40P headed engine that these headers WILL NOT WORK AT ALL, NO WAY, NO HOW:

1986-1995 5.0 stock tubular Mustang headers
stock Bronco 5.0 cast iron exhaust manifolds
1986-1995 5.0 BBK unequal length shorty headers
1986-1995 5.0 Mustang Ford Racing shorty headers

The reason those headers will NOT work or fit properly is because there is MAJOR interference with the plugs on the driver's side GT40P head. There is no way in hell to make the above headers work properly at all - period.

Now - back to the GT40P heads. I searched high and low for GT40P specific headers. True, some exist, but for the most part, 99% of the GT40P specific headers that DO exist are for the Mustangs. The problem with the GT40P Mustang headers is the ball & socket flange is skewed & designed for a Mustang and in order to make them work in a Bronco - you NEED to have a custom Y-pipe designed in order to properly mate to a Mustang GT40P header. So, my only other option I was thinking that I had would be I'd have to sell the GT40P heads and get another set of heads so that I could use a nice set of aftermarket Bronco shorty headers.

I continued to search and actually went to Ford Racing's web site. There on the Ford Racing web site, I saw the following headers - Ford Racing Part # M-9430-T50. These were specific F-Series headers for the 5.0 engine. According to all I have read online, these are a direct fit header and will mate up to the factory Y-pipe on all 1990-1995 F-Series trucks, E-Series Vans and also Broncos without any issues. There was also a side note that stated: "fits all production and GT40 heads".

Ford Racing link:
http://www.fordracingparts.com/parts...tKeyField=1332

So, I took a chance, called and ordered a set from Summit Racing (Summit Racing Part # FMS-M-9430-T50 - $295.95). The headers arrived today and it was "test" time to see if these headers would indeed fit onto GT40P heads. The headers come with header bolts, studs, nuts & nice gaskets too.

Summit Racing link:
http://store.summitracing.com/partde...5&autoview=sku


Results:

THESE HEADERS FIT the GT40P heads AND MOUNT UP GREAT!

The Ford Racing M-9430-T50 F-Series stainless steel headers bolt right up to the GT40P heads
with enough spark plug clearance that allows the removal and installation of the factory spec plugs. The trick to removing only a couple of plugs if trying to use a standard socket for spark plugs, is to insert the plug socket onto the spark plug and then use an open end or boxed end wrench to turn the plug socket (instead of using a ratchet). This worked perfectly and I tried the method by removing all plugs and reinstalling all of them - no issues with plug clearances.

There is also a company now that makes "short" spark plug sockets for tight fitting areas when removing or installing plugs (which would also come in handy for a variety of different header setups):

Product: Tight fit spark plug sockets
Price: $44.95
Manufactured by: Powerhouse Products (www.powerhouseproducts.com)



Note:
There was only 1 single issue with the set of Ford Racing headers I received. The passenger side header primary tube for the #3 exhaust port was not properly angled for spark plug clearance. Put it this way, I could not even get a spark plug boot onto the plug! This was hopefully & merely a manufacturing "oops". To remedy the problem, the tube was heated up with a torch and a ball peen hammer was used to dimple that section of tubing down enough so that the spark plug could be removed/installed and so that a plug boot would fit properly. This was the ONLY issue I came across with the set I received and like I said, I see this as being a flaw in the inspection/tolerance/manufacturing process that missed the problem before these were boxed.


All in all these Ford Racing headers are very nice and of great quality. They fit nice onto the GT40P heads and appear to have the correct ball & socket flange angles to mate with the factory Bronco Y-pipe.

So - in summary, if you are looking to install a GT40P engine and keep the GT40P heads - the above Ford Racing headers will work!

I have pics, just don't have them processed yet. I will be getting the "new" engine into the truck in the next upcoming weeks, so I'll try and take more pics of it as it sits in the engine bay.

- Phil
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post #2 of 43 (permalink) Old 05-10-2006, 09:34 AM
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cool deal very informative. will the mustang headers work on the normal 5.0 i need some headers and that may very well be an option. Doy ou still got em



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Originally Posted by SigEpBlue View Post
No, I don't have this problem. Money grows on trees here in Michigan, and my Bronco gets 45 mpg. It emits sunshine and a light berry scent, and it never needs service or parts.
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post #3 of 43 (permalink) Old 05-10-2006, 09:58 AM
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Do you think these will work on a 5.8
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post #4 of 43 (permalink) Old 05-10-2006, 11:32 AM Thread Starter
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Smile

Quote:
Originally Posted by 92EBBronco
Do you think these will work on a 5.8

For a 5.8 - you want these:
Ford Racing Part #: M-9430-T58
1990-96 F-Series Truck and E-Series Van with 5.8L engine
Fits all Production and all GT-40 heads


Ford Racing link:
http://www.fordracingparts.com/parts...tKeyField=1332

Summit Racing Part #: FMS-M-9430-T58

Summit Racing link:
http://store.summitracing.com/partde...5&autoview=sku


- Phil
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post #5 of 43 (permalink) Old 05-10-2006, 11:49 AM Thread Starter
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Talking

Quote:
Originally Posted by imlikeojnow
cool deal very informative. will the mustang headers work on the normal 5.0 i need some headers and that may very well be an option. Doy ou still got em

True - any Mustang aftermarket shorty header for a 5.0 WILL bolt onto standard production 5.0 heads (and any aftermarket head EXCEPT GT40P's). However, if trying to use Mustang 5.0 headers in a Bronco, you will still need to modify your factory or aftermarket Y-pipe to mate to the Mustang header ball flanges properly. The Mustang ball & socket flanges are angled differently than a Bronco's and therefore to use such headers in a Bronco, F-Series or E-series is not "plug-n-play".

The Ford Racing headers I listed above in both of my threads are a DIRECT fit for a Bronco (and as noted, GT40P heads, production and/or other aftermarket heads). I don't see why anyone would want to use Mustang headers (even though plentiful and sometimes a deal can be scored on used sets) in a Bronco and having to put out more cash that is needed to modify the Y-pipe to work properly. The Ford Racing F-Series headers are excellent quality, are 1 5/8" primaries, have 1 piece solid flanges, are mandrel bent and are also stainless steel - not to mention the great fitment and instant bolt on capabilities. Granted they are not cheap, but, if you want ease of installation, need to replace busted cast iron manifolds with something better and don't have the extra cash to have a shop build a new Y-pipe (or modify one), the price is a bargain price for plug-n-play headers for a Bronco.

I've had experience with the Summit Racing "cheapy" F-Series/Bronco headers on my prior 87 Bronco - and they were a PIA to work with...not only was the fitment poor, the quality was poor and due to the poor quality/fitment, no matter what was tried, they would NOT mate to the factory Y-pipe at all. I eventually had to get a new Y-pipe made by a muffler shop to the tune of $560+. So, when I thought I only could get away with $189 Summit headers on the 87 Bronco, it ended up costing me over $700 to remedy broken cast iron manifolds on the 87 Bronco.

Now that I KNOW the Ford Racing headers DO work on my current 94 Bronco w/the GT40P shortblock (and fit great), I should have just spent the $295 the last time around and it would have saved me the frustrations of the poor quality Summit headers and grief of having to have a new Y-pipe made... but hey, live & learn.

I'm putting this info out to help others, so there is now actual FACTUAL info on the Ford Racing F-series shorty headers available.

- Phil
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post #6 of 43 (permalink) Old 05-14-2006, 09:31 PM
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Where is the best place to find a factory or aftermarket Y-pipe anyway....had to cut mine out of my donor Bronc due to severe rust...yes, it will also be getting headers!

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post #7 of 43 (permalink) Old 05-14-2006, 09:41 PM
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at an exhaust shop with a bender and a welder, they can make
you anything.

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post #8 of 43 (permalink) Old 05-14-2006, 09:44 PM
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Quote:
Originally Posted by Cobra Jet
I eventually had to get a new Y-pipe made by a muffler shop to the tune of $560+.
Time to find a new exhaust shop then cuz thats 2x what my whole exhaust costed. and $110 of that was mufflers.

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post #9 of 43 (permalink) Old 05-15-2006, 08:39 AM
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So then if i have the headers specified above for the 5.8 already on the truck, and GT-40P heads in the future, i shouldn't have to much trouble with sparkplug clearance then right?

Stuff done so far: rebuilt 351w, Warn standards, Flowmaster 40 series, Bassani off-road y-pipe, FordRacing headers, B&M aux. tranny cooler, MSD cap and rotor, MSD coil, FordRacing plug wires, and Aussie locked rear

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post #10 of 43 (permalink) Old 05-15-2006, 09:32 AM Thread Starter
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If using the above Ford Racing headers for a 5.8 or 5.0 - you should not have any issues at all with spark plug clearance on any head you decide to go with.

I have not had the time to get the pictures up, but like I stated above, I'm able to remove and install ALL plugs on my GT40P heads using the Ford Racing M-9430-T50 F-Series stainless steel headers.

Also, as I noted above, I think it was 2 of the plugs, you can get a regular spark plug socket onto the plugs, but instead of using a ratchet, you will need to use a box or open end wrench on the end of the spark plug socket to remove the plug - NO BIG DEAL. You can also opt to purchase the shorty spark plug removal socket from Powerhouse Products which I also supplied the info to them above.


- Phil
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post #11 of 43 (permalink) Old 05-15-2006, 10:30 AM
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Lucky you, are you talking regular Autolites or ACCell headerplugs??? I had one on my MAC's that you couldnt even install a regular socket, 1 you had to use about 16" of extension and do it threw the wheel well, and most of them you needed socket/wrench to take out.

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post #12 of 43 (permalink) Old 05-15-2006, 12:53 PM Thread Starter
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Quote:
Originally Posted by 81Bronk36
Lucky you, are you talking regular Autolites or ACCell headerplugs??? I had one on my MAC's that you couldnt even install a regular socket, 1 you had to use about 16" of extension and do it threw the wheel well, and most of them you needed socket/wrench to take out.

removed regular Motorcrafts, installed regular Autolites - no special header plugs used. I have seen the Accel "header plugs", but, I'm not going to spend $40-50+ for spark plugs when I can work with the regular spec plugs.

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post #13 of 43 (permalink) Old 05-15-2006, 08:44 PM
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my bbk shortys fit gt40 p heads fine, though cly #7 needs a 90 deg boot on the spark plug

Kyle
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post #14 of 43 (permalink) Old 08-11-2007, 06:41 AM
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i wish i found this from the start...

i just went through all this, what cobra jet states is 100 percent true, cause i had the stock manifolds, stock 5.0 headers, and bbk headers. the bbk headers would have worked DECENT if i had not swapped to a manual theres no clearance for the slave cylinder

furthermore, before the swap i had a custom y for the stang headers, and with the different stang exhaust outlet, its a PITA to get clearance especially by the front driveshaft
now i gotta throw the custom fabbed (by myself) y pipe out! i got the slag scars, they aint worth it!
for anyone gt40p or not i recommend NOT to go with stang headers! its more $ especially if youre keeping the truck for awhile

so if your running gt40p (well worth it IMO) get the ford racing headers OR use stock explorer manifolds to hold you over....they work, just really restrictive looking...yeah its a jackass move...but i need the truck done today

k later goin to my guy at meineke


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post #15 of 43 (permalink) Old 02-11-2008, 05:37 PM
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so, anyone have any more info on these headers for the gt40 p's?


black 96 5.8 xlt sport, e40d, edelbrock intake, bassani y-pipe, bilstien shocks, 32"bfg's
azure blue 03 mach1 4.6 dohc


"Sorry - no matches. Please try some different terms."
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post #16 of 43 (permalink) Old 02-11-2008, 10:05 PM
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post #17 of 43 (permalink) Old 02-11-2008, 10:15 PM
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i'm searching myself blind/insane. i have read the above post must have missed the part number


black 96 5.8 xlt sport, e40d, edelbrock intake, bassani y-pipe, bilstien shocks, 32"bfg's
azure blue 03 mach1 4.6 dohc


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post #18 of 43 (permalink) Old 02-27-2008, 02:51 PM
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Great info, tagging this for my rebuild reference ~
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post #19 of 43 (permalink) Old 03-10-2008, 03:32 PM
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Cobra Jet ~ PM sent, I really like this concept so far!

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post #20 of 43 (permalink) Old 03-10-2008, 03:45 PM
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nice job man..i say thanks from all of us...now if i could find gt40 heads...so rare in every j/y around me in south jersey
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