JBA Headers, Cat, 2.5” Pipe, Aftermarket Muffler on a Automatic 2.9L?

[Ranger101]

Fellow Rangers,

As my profile shows, I’m a 89 automatic, 2WD, 2.9L kind of guy. For now.

Reading through various threads, I’ve gathered that JBA stainless headers (I only found them on the JBA website and for a manual none the less), keeping the cat, 2.5” pipes, and your individual choice of aftermarket muffler (depending on sound choice) is a path for me personally to take.

I’m not a tuner. Just an oridinary guy who likes his truck. This will be a get around town truck to show respect to the truck, the era, and the brand. It will look great, surprise people at lights with power and quickness, and be a conversation piece for years to come. I have all intentions of doing/installing the exhaust components listed in the paragraph above while keeping the 2.9L and the 2WD automatic (original A4LD) transmission (having it rebuilt). I’m at the beginning of my journey and want your positive input on what you all think of my course of action, your experiences, and your suggestions.

Feel free to comment on such topics as going from Y pipe to H pipe, pre-rear tire or rear end exhaust location, header installation, changing or keeping different components of the existing exhaust system, other aftermarket options, etc. The floor is yours.

Here we go and thanks in advance.

 

[JohnnyO]

On a small engine headers help a little but not a lot. So get the headers assuming they will work with an automatic, Magnaflow makes low-restriction universal cats, and the muffler is up to you but I have a Flowmaster DBX on my Sport Trac that I like a lot or Gibson probably has a full cat-back system. I used to have the Gibson but it's kinda loud.

PetroleumJunkie412 is the 2.9 guru.

 

[Ranger101]

On a small engine headers help a little but not a lot. So get the headers assuming they will work with an automatic, Magnaflow makes low-restriction universal cats, and the muffler is up to you but I have a Flowmaster DBX on my Sport Trac that I like a lot or Gibson probably has a full cat-back system. I used to have the Gibson but it's kinda loud.

PetroleumJunkie412 is the 2.9 guru.

Thanks for the reply JohnnyO.

I haven’t been able to find a set of headers that will fit the automatic.

I appreciate the heads up on the Gibson. I don’t want it to be loud. I’ve got in mind to keep the stock exhaust manifolds and go 2.5” to the tailpipe. I plan on enlarging the air pipe to the filter box and put a K&N filter after modifying the box. Air in and air out.

I agree, PJ412 is the 2.9 Guru.

 

[JohnnyO]

I agree, PJ412 is the 2.9 Guru.

See if he knows what the difference might be and if the headers would work with an automatic. My guess is the shift linkage but I can't say for sure. One of those things that might be small and fixable with a ball peen hammer.

 

[PetroleumJunkie412]

Base headers should be the same. They sit half inside the frame rails.

Take to muffler shop. Tell them you're changing heads, and see if they'd be willing to replace manifold bolts. Picked that up off @RonD.

Use copper anti seize and gasket spray. You will **** yourself if you do not. Every threaded connection exhaust side.

Every one. Even stuff like egr plugs. You never know.

I can't find replacement header gaskets, only manifold. Looking for other options, stock gaskets suck. Theyre paper thin, and headers flex, so need thick ones with steel mesh and give. Try to preserve if possible.

Y pipe will likely be different. If it fits, cool.


If it does not, easy fix. Put the A4LD back in hell where it belongs, and replace with manual of choice.









Or take to same muffler shop with manual y pipe and say "make work please" they will. Look for an "& sons" establishment. Ask for the father.

 

[PetroleumJunkie412]

No matter what, you have headers in either situation. Real shop will charge less than $150 for y pipe, would be surprised if more than $80.

Meinikie will want $500. So. **** them. The cost of corporate.

 

[PetroleumJunkie412]

But seriously save the small town shops on this one. Exhaust is an art. Your dollars go far here.





And because rust in your eyes ****ing sucks. These guys are willing to do it for a living.

 

[gaz]

Ranger101:

I put a set of JBA tripple Ni plated headers on both an 87 2.9L with A4LD and an 87 2.9L the FM145 manual transmission, they are EXACTLY the same. In regards to what I was told to expect from adding headers to my 2.9, my mechanical mentors were all in agreement that I should expect about 20 hp with a similar compliment of torque if used with 2¼" tubing on a stock 2.9L engine. I was very impressed with the difference I felt driving but even more impressed with the improvement in fuel economy!!!

I don't know if you are aware but your 89 uses a 2 to 1 "Y" pipe, the 86-87's came with a 2 to 2 "Y" pipe. If you are considering duals or the use of a X-pipe the older style "Y" and flange can facilitate this very inexpensively.

When I built the exhaust for a built 2.9, I used 2 to 1 into the cat and a single 2½" from the cat on out.

In regards to a muffler Choice, I like a performance sound but not too loud on a truck. I chose the Borla Turbo style; they now have several more choices, regarding sound but the reason I chose Borla was purely for good flow and SOLID build quality. Later when I needed to use a 2½" system vs the original 2¼", I went with a Borla XR1 because I wanted no flow loss from the muffler. The XR1's do cash in on the raspberries but still have a solid "performance engine" sound ..)

One other thing I was STRONGLY advised on when I was preparing to use headers was to use locking header bolts. I chose Stage8 locking header bolts and have not had either a leak or need to tighten a header bolt ever; those headers went on in 1998.

 

[sheep herder]

And because rust in your eyes ****ing sucks.

True. Been there, done that.

 

[Ranger101]

Fellow Rangers,

I appreciate the input. It is highly valued and I will put it to good use.