1999-2003 Ford F-150 5.4L V8 Long Tube Headers - Stainless Steel w/ O2 Bungs & EGR Port - Performance Exhaust Upgrade

SKU: XKV11061
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Fitment & Specs
Fits selected Ford 5.4L V8 applications, including 1999–2003 F-150, 2004 F-150 Heritage, and 1997–1999 F-250. For Lightning and Harley Davidson Edition, fits 5.4L V8 supercharged models only. Verify model year, engine, trim, O2 sensor layout, EGR connection, and exhaust compatibility before purchase.
8 × 1.625" Ports Inlet · 2.375" Outlet
T304 Stainless Steel · Long Tube Headers with O2 & EGR Bungs
Before You Buy: Off-road/racing use only · Professional install recommended · Tuning may be required
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Description

This stainless steel long tube header set is designed for page-listed Ford 5.4L V8 applications, including selected F-150, F-150 Heritage, F-250, Lightning, and Harley Davidson Edition models shown in the fitment information below. It is intended as an exhaust header replacement or upgrade-style component for compatible Ford 5.4L exhaust setups.

Built from T304 stainless steel with CNC-machined flanges, TIG-welded construction, 8 x 1.625" diameter ports, 2.375" outlets, 1.625" manifold piping into 2 x 2.500" exhaust pipes, O2 sensor bung provisions, EGR bung provisions, and metal gasket included as listed, this header set is designed to support a secure exhaust path where compatible. Final fitment, sound, exhaust sealing, drivability, and performance results may vary depending on vehicle condition, exhaust layout, O2 sensor setup, EGR connection, installation quality, emissions setup, and supporting components.

Product Overview

This product is a long tube exhaust header set for compatible Ford 5.4L V8 applications. It is not a catback exhaust system, downpipe, turbocharger, complete exhaust system, universal header kit, or full emissions delete product. Please verify your exact model year, trim, engine, supercharged application where applicable, flange layout, O2 sensor position, EGR hookup, exhaust connection, and emissions requirements before purchase.

Key Details

  • Fitment: Page-listed Ford 5.4L V8 applications
  • Product Type: Long Tube Exhaust Header Set
  • Material: T304 stainless steel as listed
  • Header Design: 2 x 4-2-1 racing-style design as listed
  • Inlet / Port Size: 8 x 1.625" diameter ports as listed
  • Outlet Size: 2.375" as listed
  • Piping Reference: 8 x 1.625" manifold piping into 2 x 2.500" exhaust pipes as listed
  • Sensor / EGR Provisions: O2 sensor bungs and EGR bung provisions as listed
  • Included Components: Metal gasket included as listed
  • Construction: TIG-welded CNC-machined flanges as listed
  • Installation: Professional installation highly recommended
  • Instruction: No installation instructions included unless otherwise stated on the product page
  • Use Case: Off-road, racing, or closed-course use where emissions laws apply

Fitment

Please use the table below to quickly confirm the main vehicle applications currently listed for this Ford 5.4L header set. Before ordering, verify your exact model year, trim, engine, supercharged application where applicable, O2 sensor layout, EGR hookup, flange connection, downstream exhaust layout, and emissions setup.

Vehicle Name Year Engine Notes
Ford F-150 1999–2003 5.4L V8 Verify trim, exhaust layout, O2 sensor position, EGR hookup, and flange connection
Ford F-150 Heritage 2004 5.4L V8 Verify Heritage model configuration and exhaust connection layout before purchase
Ford F-250 1997–1999 5.4L V8 Page-listed fitment; verify exact F-250 configuration before purchase
Ford Lightning / Harley Davidson Edition Page-listed applications 5.4L V8 Supercharged Listed for Lightning and Harley Davidson Edition 5.4L V8 Supercharged models only; verify exact application
Fitment Note: This table is based on the fitment information currently listed for this product. The product title focuses on 1999–2003 Ford F-150 5.4L, while the page-listed fitment also includes 2004 F-150 Heritage, 1997–1999 F-250, and Lightning / Harley Davidson Edition 5.4L V8 Supercharged applications. Please verify your exact model, trim, engine, supercharged application where applicable, O2 sensor layout, EGR hookup, flange connection, and emissions setup before purchase.

Package Includes

  • Long tube exhaust header components as shown
  • O2 sensor bung provisions as listed
  • EGR bung provisions as listed
  • Metal gasket included as listed
  • Hardware, bolts, or additional accessories included only if shown or listed

Please review the product photos and listing details before installation. Confirm all included headers, gaskets, flanges, O2 / EGR provisions, fasteners, and connection requirements against the received package before beginning installation.

Installation Notes

  • Professional installation is highly recommended.
  • Test fit both header sides before final tightening.
  • Verify cylinder head flange alignment, gasket seating, O2 sensor position, EGR hookup, collector connection, and downstream exhaust compatibility before installation.
  • Check clearance around the steering shaft, starter, transmission, frame, firewall, suspension components, wiring, heat shields, and surrounding exhaust components.
  • Verify O2 sensor wire reach and EGR connection compatibility before final assembly.
  • Old, rusted, or seized factory hardware may increase installation difficulty.
  • Modified exhaust systems, previous repairs, engine swaps, or non-factory configurations may require additional adjustment or fabrication.
  • Inspect all exhaust connections for leaks after installation and recheck fasteners after initial heat cycles where appropriate.

Before You Buy

  • This product is intended for page-listed Ford 5.4L V8 applications only.
  • This is a long tube exhaust header set, not a catback exhaust system, downpipe, turbocharger, complete exhaust system, universal header kit, or full emissions delete product.
  • Please verify your exact model year, trim, engine, supercharged application where applicable, flange layout, O2 sensor position, EGR hookup, downstream exhaust connection, and emissions setup before purchase.
  • Lightning and Harley Davidson Edition applications are listed for 5.4L V8 Supercharged models only; verify exact vehicle configuration before ordering.
  • This product may alter the factory exhaust or emissions-related configuration depending on the vehicle setup.
  • This product is intended for off-road, racing, or closed-course use where emissions laws apply.
  • This product is not represented as street legal, emissions-compliant, CARB-compliant, or legal for public road use unless explicitly stated.
  • Performance gains, sound changes, exhaust flow changes, fitment, clearance, and drivability results are not guaranteed and may vary by setup.
Shipping & Return

SHIPPING & DELIVERY
Fast Processing & Reliable Transit

  • Processing: Orders are processed and shipped from the nearest available warehouse within 1 business day after payment.
  • Delivery: Estimated delivery time is approximately 3–4 business days after shipment.
  • Shipping - Free shipping on all orders within the contiguous 48 U.S. states.

RETURNS & EXCHANGES
30-Day Hassle-Free Policy

  • Return Window: We offer a 30-day return policy from the date of delivery.
  • Item Condition: Returned items should be unused, uninstalled, and in their original packaging when possible.
  • Return Process: To initiate a return or exchange, please contact our customer service team first to receive authorization and instructions.

WARRANTY
2-Year Limited Replacement Warranty

  • Duration: All products are backed by a 2-year limited warranty.
  • Coverage: This warranty covers manufacturing defects and product failures under normal use, and provides a replacement for qualified cases (repairs are not performed).

CUSTOMER SUPPORT
We’re Here to Help – Contact Us First

  • Priority Contact: For any order-related issues—including returns, warranty claims, or general inquiries—please contact us first before taking further action. We are committed to resolving your concern promptly.
  • Feedback Notice: If you are unsatisfied, we kindly ask that you allow us an opportunity to address the issue before leaving neutral or negative feedback.
  • Email Support: You can reach us at support@XKVracing.com.

What Does an Exhaust Header Actually Do?

The exhaust header is the first section of the exhaust system and mounts directly to the engine. Its role is to collect exhaust gases from each cylinder and route them into the rest of the exhaust system.

Compared to many factory manifolds, header designs often focus on smoother internal flow and more uniform exhaust routing before gases move downstream.

What You May Notice After Installation

Smoother exhaust flow as engine speed increases

More consistent engine behavior across the RPM range

Improved exhaust routing when paired with other intake or exhaust components

Changes in exhaust tone, depending on system configuration

When This Type of Upgrade Is Typically Considered

Addressing airflow limitations in the factory exhaust manifold

Planning coordinated intake or exhaust system updates

Replacing aging or restrictive original components

Build a balanced, performance-focused setup

Factory Manifold vs. Performance Header

Factory Exhaust Manifold

Designed to meet packaging, cost, and emissions requirements
Prioritizes durability and compliance across broad use cases

Performance Exhaust Header

Designed with exhaust flow characteristics in mind
Built for higher exhaust temperatures and specific vehicle platforms
Commonly used as part of an exhaust system configuration

FAST SHIPPING

Ships within 1 business day after payment
3–4 business day delivery

Secure and Reliable Checkout

Secure checkout with major payment options

LOCAL WAREHOUSE

Orders ship from U.S. warehouses when available

Easy Returns and Exchanges

30-day returns for eligible unused items

Parts Warranty

Warranty support for qualified manufacturing defects

Important Notice

Products on this site are intended for off-road, racing, or closed-course use where emissions laws apply. They are not represented as street legal, emissions-compliant, or legal for use on public roads unless explicitly stated.

Some products may remove, replace, relocate, disable, or alter emissions-related components, including but not limited to catalytic converters, EGR, DPF, SCR, DOC, O2 sensors, or related factory systems. Compatible tuning, calibration, or supporting modifications may be required to avoid engine codes or drivability issues.

Professional installation is recommended. Buyers are responsible for verifying product compatibility, local regulations, emissions requirements, and any required tuning or supporting modifications before purchase and installation.

Performance gains, sound changes, airflow improvements, temperature changes, fuel economy changes, fitment, and drivability results may vary. No specific performance gains are guaranteed.

Frequently Asked Questions

What do exhaust headers do? +

Exhaust headers help route exhaust gases away from the engine through individual tubes and collector-style routing. Actual results depend on the vehicle, engine condition, exhaust system, installation quality, and supporting components.

What's the difference between headers and factory manifolds? +

Factory manifolds are typically designed around packaging, durability, emissions requirements, and production cost. Headers or manifold-related exhaust upgrades may use different tube routing, flange designs, or connection layouts depending on the application.

Will headers increase horsepower? +

Headers may support improved exhaust flow where the product is compatible, but horsepower and torque changes are not guaranteed. Results vary by engine setup, tuning, exhaust configuration, vehicle condition, installation, and supporting modifications.

Do headers make the vehicle louder? +

Headers and related exhaust parts can change exhaust tone and may increase sound depending on the rest of the exhaust system. Final sound level depends on the engine, mufflers, catalytic converters, pipe routing, and complete exhaust setup.

Do I need tuning after installing headers? +

Tuning requirements depend on the vehicle, engine management system, O2 sensor setup, emissions equipment, and supporting modifications. Some installations may not require tuning, while modified builds may require professional inspection, calibration, or tuning to support proper drivability.

Are header products street legal? +

Header and exhaust products may be intended for off-road or racing use where emissions laws apply. They are not represented as street legal, emissions-compliant, or CARB-compliant for public road use unless a valid exemption is explicitly stated. Always check local regulations before purchase and installation.

Can I use headers with a stock exhaust system? +

Compatibility with a stock exhaust system depends on the vehicle and existing exhaust configuration. Some vehicles may require additional hardware, gaskets, connectors, adjustment, or fabrication to complete installation.

Are headers hard to install? +

Installation difficulty varies by vehicle. Tight engine bays, old hardware, rust, engine swaps, modified exhaust systems, sensor placement, and clearance around surrounding components can increase installation complexity. Professional installation is recommended.

Will headers affect reliability? +

Reliability depends on fitment accuracy, installation quality, vehicle condition, heat management, gasket sealing, fastener condition, sensor placement, and supporting components. Proper inspection and installation are important.