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Just trying to make sure I'm not missing anything as I get ready for the head swap. Does the 96 require a thermaxtor port in the head or can I get undrilled heads?

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My 5.8 never had an AIR pump or any of the Thermactor system installed on it. I'm not sure if the 5.0 had it or not.
 

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Man of endless projects
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302 used smog pump and thermactor in heads. 351 in light trucks (under a certian GVWR) did not have smog pump or thermactor. vehicles over that GVWR have smog pump but a differentsetup that had thermactor on each tube of the manifolds instead of the heads
 

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ate lug
88 + 96 broncos, 96 F250
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i believe it was 8800# GVWR. So the 96 F150/bronco would have the mass air 351 with no smog pump, but the F250+ (any truck above 8800#), would have the speed density 351, with that smog pump with the dual thermactor tubes.
 

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Yo mumzer,
Our 96 Bronco 5.0, bought new has a Thermactor system with smog pump and air injection.
The 96 Bronco 5.8 wasn't built with the system.

1996 MY OBD System Operation Summary for Gasoline Engines
"...The mechanical AIR system uses a belt-driven pump as well as a check valve to deliver air into the exhaust system where required. The belt-driven air pump runs continuously so a bypass valve and/or diverter valve is used to direct airflow to the exhaust manifold (upstream air), the COC catalyst (downstream air), or directly to atmosphere (bypass/dump). The Mechanical AIR pump flow check monitors the HO2S signal at idle to determine if secondary air is being delivered into the exhaust manifold (upstream). The air/fuel ratio is commanded open-loop rich, the AIR bypass/diverter valves are directed upstream, and the time required for the HO2S signal to go lean is monitored. If the HO2S signal does not go lean within the allowable time limit, a low/no flow malfunction is indicated. (P0411). If the vehicle is equipped with a COC catalyst, the downstream air delivery as well. The air/fuel ratio is commanded open-loop rich, the AIR bypass/diverter valves are directed downstream, and the time required for the HO2S signal to go lean is monitored. If the rear HO2S signal does not go lean within the allowable time limit, a low/no flow malfunction is indicated. (P1411). The PCM outputs that control the bypass and diverter valves are checked for circuit continuity (P0413, P0414 Bypass valve), (P0416, P0417 Diverter valve). ●
Currently, the 4.9L E and F-Series, 5.0L E and F-Series, and 7.5L F-Series incomplete vehicles utilize mechanical air system..."
READ MORE

Source: by Ford motorcraftservice.com
 

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85 Bronco, 309ci I6 w/4bbl, np435, 4" lift, 37" Irok NDs, 4.56 w/ Detroit Locker and tru trac
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i believe it was 8800# GVWR. So the 96 F150/bronco would have the mass air 351 with no smog pump, but the F250+ (any truck above 8800#), would have the speed density 351, with that smog pump with the dual thermactor tubes.
Bingo. Though mostly it was F350 and just a few F250 that were exempt from the 96 OBDII mandate. My 96 RCLB F350 has a 9100 GVWR and had all the smog equipment and exhaust manifold air injection. Had a C6 trans too
 
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