1992 Ford F-150 - Headers, Exhaust & Starter Install

Project Fiery Redhead - Part 1
Project Fiery Redhead - Part 2
Project Fiery Redhead - Part 3
Project Fiery Redhead - Part 4
Project Fiery Redhead - Part 5
Project Fiery Redhead - Part 6
Project Fiery Redhead - Part 7
Project Fiery Redhead - Part 8
Project Fiery Redhead - Part 9
Project Fiery Redhead - Part 10

Up to this point we've mostly ignored the 302ci V-8 engine in our project F-150, and now it's time to show it some love. Of course we have ulterior motives, namely, power and reliability.

We've addressed both of these issues with a pair of simple yet effective modifications. The first is a complete Bassani exhaust system with headers. We chose Bassani because they're one of the leading exhaust manufacturers with a reputation for excellent fit and performance. We began by replacing the stock exhaust manifolds with a pair of Bassani's nickel-plated headers.

The new Mean Green gear-reduction starter next to the stock unit. Even though it produces far more starting power and torque than the stocker does, it isn't overly bulky. As a matter of fact, ours bolted right in without any modifications to the truck. Ford, AMC/Jeep, and Toyota starters can be rotated in 20-degree increments for better header clearance if needed. GM starters have dual bolt patterns for both the 153- and 168-tooth flywheels. MG Industries also manufactures starters for a wide variety of vehicles in both gasoline and diesel applications.

The new Mean Green gear-reduction starter next to the stock unit. Even though it produces

These optimum-length headers use mandrel-bent 14-gauge carbon steel primary tubes for durability. They also feature Bassani's exclusive Extractor Collector, which induces a scavenging effect and further improves performance. They come with S.S. Comp stainless header gaskets that cure header leaks, and gasketless ball and socket connectors. Downstream, we ditched the rest of the restrictive factory system and installed a Y-pipe, optional catalytic converter, and 3-inch-diameter single Quiet Thunder after-cat system with Quiet Thunder muffler. The kit we chose routes the pipe over the axle and out the stock location.

Second, we installed a new, heavy-duty gear reduction starter from MG Industries. Since this truck is going to be used for work as well as play, we wanted a super-durable starter, and the MG Industries unit is built like a tank compared to the OE starter. Its list of features is mind-boggling and it sports a bunch of goodies that appeal to us 'wheelers and the extreme conditions we encounter.

It has a 4.4:1 gear reduction; a massive 3-inch-diameter tool steel driveshaft that's supported at both ends by bearings; is sealed against water intrusion; it's cold-weather resistant; uses less amperage than stock units; has an integrated solenoid that is corrosion-proof; and it's built with five sealed ball bearings to enhance mechanical efficiency and reduce wear. Further, an independent lab says the unit produces 100 percent more torque and 200 percent more starting power than stock units. For those of you with manual transmissions, this could be just what the doctor ordered, because this beefy unit offers the durability needed to pull your vehicle when using the starter to creep over rocks and obstacles.

The guys at the Redhead's official buildup shop, Attitude Performance in Arlington Heights, Illinois, had the Bassani exhaust and the Mean Green starter on in a flash while we took photos. The 'ol Redhead now has a pleasing exhaust note, the performance gains that accompany a free-flowing exhaust, and a starter that can put out some serious spin.

The stock manifolds compared to a new Bassani header. We didn't know our stock manifolds were cracked until they broke apart after we removed them from the engine. Cracked manifolds are common on older engines. Sometimes you can hear them ticking--other times you can't.
The stock manifolds compared to a new Bassani header. We didn't know our stock manifolds w
We accessed the manifolds by removing the inner fender liners. This gave us mostly unobstructed access without having to hang into the engine compartment. Surprisingly, we were able to remove all of the exhaust-manifold bolts without any of them snapping off. The oxygen sensor even unscrewed from the pipe without a problem. After installing the S.S. Comp header gaskets, the new headers slipped right into position.
We accessed the manifolds by removing the inner fender liners. This gave us mostly unobstr
The rest of the exhaust system simply slipped together and was secured with clamps. The installed system is trail-friendly. It fits snugly against the bottom of the truck with no protruding components that could get caught on obstacles. The new Y-pipe crosses under the transmission, but doesn't hang lower than the transmission pan.
The rest of the exhaust system simply slipped together and was secured with clamps. The in