Analysis Paralysis; 2.9 build exhaust

[Gunfighter97]

Hey all, first post here though I have been lingering for a few years with my 87 Ranger XLT 4x 2.9. Lots of valuable info here, but I finally cant quite find the answer I'm looking for. Skip to the end if you dont want to read it all

The bugger cracked a head, and though I'm not throwing my existing engine away, I am building a new one for now on a Mabbco short block that I'll tear down and double check everything (as semi hated as the 2.9 seems to be, I like the little guy). And my qestion is about what parts will bolt together.

I have read the 4.0 headers will bolt up to the 2.9 heads. There is a header and two piece Y-pipe kit made by JBA for 95-97 4.0 rangers that appears to tick all the boxes. It has the egr port on the correct side (I dont want to mess with my computer if I dont have to) and a socket that will mount (or I can make mount if not) the O2 sensor. The flange looks like it will fit the 1989 and on cat that I already have. I can fabricate a new copper EGR tube easy enough.

Dont have much in the way of large tube bending stuff to mod the Y-pipe but could probably fabricate tools to do it if I had to and/or wanted to.

The engine I'm building is simply going to be a very clean looking 2.9 that'd likely only be considered as stock plus. Mabbco is adding a mild cam to bump up the low end torque and I may do some things with valves depending on whats involved as long as it doesn't play havock with the computer or mileage. Its going in with a new sachs clutch/flywheel, heavy duty radiator, and probably an electric fan. I'm assembling the heads on new wide rocker stand base type head castings that I believe are ATK going off casting numbers (6090) I think these are the heavier heads people seem to like over the stock ones with deck cracking problems. I don't want and am not expecting a race car, just a long lived truck with a little more nudge for the high elevation where I live.
I am pulling a lot of new sensors, and miscellaneous bits from my old engine (especially anything I recently replaced). Am open to hearing about other mods that might give it a little more edge or longevity while Im in there. I have thrown my budget for this truck to the wind, as all of this happened as I began heavily sprucing up the interior and already sunk more into it than I will ever get for it.

TLDR: Anyone happen to know if the 95-97 4.0 y-pipe system pictured will clear the frame on a first gen 4x? Or can be made to clear with some minor cuting? I dont have tube bending stuff . . . Yet >

 

[SenorNoob]

I know nothing about headers... But with factory parts, I have stock 2.9 y-pipe on my 4.0.

A short search says 2.9 and 4.0 headers are compatible except maybe the y-pipe. Which doesn't make any sense to me...

 

[broncc]

One small hiccup... I recall my 2.9 only have one oxygen sensor. Neither of the locations included in that kit will be acceptable. You or someone else with welding skills will need to add a bung after both banks connect.

 

[SenorNoob]

^This is true. Partly why I used the 2.9 y on my 4.0. My PCM needed a single O2 just before the cat. The engine came from a truck that had 2.

 

[Gunfighter97]

One small hiccup... I recall my 2.9 only have one oxygen sensor. Neither of the locations included in that kit will be acceptable. You or someone else with welding skills will need to add a bung after both banks connect.

If what I'm picturing is correct, that'd be aft of where the two banks intersect into one pipe before the cat? Almost tempted to make my own. I just don't want to spend the time.

Wouldn't be terribly hard to modify I suppose. I dont know yet if I'm entirety sold on the idea of adding headers. Seems like nobody makes an aplication specific solution anymore so finding thats gonna turn into an ebay adventure. My entire system was rotted end to end, and I couldn't find a correct H style Y-pipe so I went to an 89 Y and cat, then my drivers side head decided to disintegrate before I could install any of it.

Thanks for the replies! And Happy 4th!!!

 

[SenorNoob]

You got it. Like this one:
Walker 40205

BTW, that's what I'm using.

 

[lil_Blue_Ford]

You could put a weld-in bung in the Y section and plug the unused holes in headers for different applications…

I would see if they can balance the internals of the 2.9 by the way, that’s supposed to help. Really, if I was having a 2.9 rebuilt, I’d do as much as possible to build it up. Sven Pruitt I think it was had a whole book on it and I know some stuff is in the tech archives on here.

 

[Gunfighter97]

You got it. Like this one:
Walker 40205

BTW, that's what I'm using.

Thats exactly what I have. The only reason I'm considering the headers is (purely speculative) letting the little guy exhale better and possibly stay a little cooler up top than have all those hot exhaust gasses go by the same two rear cylinders.

You could put a weld-in bung in the Y section and plug the unused holes in headers for different applications…

I would see if they can balance the internals of the 2.9 by the way, that’s supposed to help. Really, if I was having a 2.9 rebuilt, I’d do as much as possible to build it up. Sven Pruitt I think it was had a whole book on it and I know some stuff is in the tech archives on here.

Doesn't ballance require the flywheel and clutch assembly? I'm admitedly pretty new to performance jobs. This is my first crate engine, but I've worked heavily on a lot of engines over the years from small nitro methane model engines to the BG265 six in my 1966 Loadstar 4x4, but I digress. Taking in customer parts for a build is the one thing these guys never ever do from what I was told over the phone, and all they do is short and long blocks, no flywheels. Though I might be able to do that job myself dpending. Will have to look for that book!
Edit: got that book