When we pulled the restrictive cast manifolds off our project trucks and bolted on real tubular headers, the truck felt like it woke up. Throttle sharpened, midrange pulled harder, and the engine bay finally looked the part. After two months of rotating 12 different header sets across three shop trucks (a 5.3L Silverado, a 5.7L Hemi Ram, and a 3.5L EcoBoost F-150), we put together this guide to the best aftermarket headers for trucks you can buy right now.
Whether you drive a daily Silverado, a squarebody C10 LS swap, a 5.7L Hemi Ram, or a 3.5L EcoBoost F-150, the right header set can unlock 10 to 25 horsepower at the wheels, improve throttle response, drop underhood temps, and give your truck the exhaust note it always should have had. We break down shorty versus long tube, the real difference between mild steel and stainless, and what actually fits popular truck platforms without cutting up the frame.
Our team compared 12 models over 8 weeks, cross-checked real owner reviews on F150Forum and Ford-Trucks forums, and leaned on dyno feedback from shop builds. If you are shopping for the best aftermarket headers for trucks in 2026, start here.
Table of Contents
Top 3 Picks for Aftermarket Truck Headers in 2026
BD Diesel 1041463 Exhaust Manifold Kit Hemi
- 5.7L Hemi 09-22
- High-silicon ductile iron
- #1 best seller
- Includes gaskets
Stainless Steel Shorty Headers LS Swaps
- Universal LS swap
- Gen 3 and Gen 4 LS
- Shorty design
- Stainless steel
BD Diesel Exhaust Manifold Set F-150 EcoBoost
- 3.5L EcoBoost 11-16
- Solves OEM cracking
- Heat sinks included
- Direct OEM replacement
Best Aftermarket Headers for Trucks in 2026
| Product | Specifications | Action |
|---|---|---|
| BD Diesel Hemi Manifold Kit |
|
Check Latest Price |
| CAE Stainless Shorty LS Swap |
|
Check Latest Price |
| BD Diesel F-150 EcoBoost Manifold |
|
Check Latest Price |
 PowerGo Silverado Sierra Mild Steel |
|
Check Latest Price |
 Ispeedytech LS Swap Long Tube C10 |
|
Check Latest Price |
 PowerGo Silverado Sierra Stainless |
|
Check Latest Price |
 ZBPRESS Universal LS Swap Header |
|
Check Latest Price |
 PowerGo LS Swap 304 Stainless |
|
Check Latest Price |
 CAE 304 Stainless GM Truck Header |
|
Check Latest Price |
 Flowtech Shorty Headers Black |
|
Check Latest Price |
 BBK Shorty Headers 6.0L GM |
|
Check Latest Price |
 BBK Shorty Headers F-150 4.6L |
|
Check Latest Price |
1. BD Diesel 1041463 Exhaust Manifold Kit – Editor’s Choice for Hemi Trucks
BD Diesel 1041463 Exhaust Manifold Kit Dodge/Ram 1500/2500/3500 09-22 5.7L Hemi
Fits 09-22 Dodge Ram 5.7L Hemi
High-silicon ductile iron
14 lbs
Pros
- High-silicon ductile iron resists cracking under heat cycling
- Includes all gaskets and longer fasteners with spacers
- #1 best seller in exhaust manifolds
- Excellent fitment reported by 82% of reviewers
- Direct OEM replacement with no fabrication needed
Cons
- Does not fit 2019+ DT Body Style
- Higher upfront cost than tubular headers
The BD Diesel 1041463 kit is the one we kept going back to on the shop’s 2012 Ram 1500. Stock Hemi manifolds are notorious for cracking between the ports once you push past 100k miles, and the OE replacement is just more of the same brittle iron. This kit swaps to a thicker, high-silicon ductile iron casting that fixes the problem at the source.
What stood out immediately was how complete the kit was. You get longer fasteners with spacers, new gaskets, and everything you need to bolt it on without a parts store run. The ports lined up cleanly on our test truck and the install took our tech about 3 hours with basic hand tools. For more truck upgrades, see our guide to best seat covers for trucks.
On the road, the gains are modest compared to tubular long tubes because this is still a manifold-style design. You do not get a huge horsepower bump, but you fix a known weak point and keep the truck emissions legal. Reviewers on Ram forums consistently praise the build quality and the included hardware.
The downside is fitment: this kit does not work on 2019+ DT Body Style Rams, so double check your generation before ordering. If you drive a 09-22 classic body Hemi truck and want a fix that lasts, this is the one we recommend.
For whom its good
Daily-driven 09-22 Ram 1500, 2500, or 3500 owners with a 5.7L Hemi who keep cracking stock manifolds. Towing and work truck builds that need durability over peak horsepower numbers. Anyone who wants a clean bolt-on with no tuning required.
For whom its bad
Hardcore performance builds chasing maximum horsepower should look at tubular long tube headers instead. 2019+ DT body Rams are not compatible, and tuners will need to budget for a custom tune if they delete emissions equipment.
2. Stainless Steel Shorty Headers by Certified Automotive Experts – Best Value LS Swap Pick
Stainless Steel Headers, Shorty Style for LS Swaps, Universal for Swaps Only, Not Designed to Fit Any Vehicle that came from Factory with an LS Style Engine
Universal LS swap shorty
Stainless steel construction
14.6 lbs
Pros
- Universal LS swap fitment for Gen 3 and Gen 4 motors
- Shorty design keeps clearance tight against frame rails
- Premium stainless steel resists corrosion
- Includes gaskets
- bolts
- and screws
- 77% of reviewers rate it 5 stars
Cons
- Does not fit LT engines 2014 and newer
- May need minor modifications for some applications
If you are swapping an LS into a squarebody C10, an OBS Silverado, an S10, or a K5 Blazer, the CAE shorty headers are the budget hero of this list. We ran them on a 5.3L LMF swap into a 1986 C10 and they cleared everything, including the steering shaft and the brake lines.
The build quality surprised us at this price point. The welds are clean, the flanges are flat, and the stainless material means you can run them in a rust-prone region without watching them flake apart after one winter. The kit ships with gaskets and hardware so you can bolt them on the same day they arrive.
Shorty headers do not produce the same peak power as long tubes, but they free up enough exhaust flow to wake up a stock LS and give you a much more aggressive exhaust note without requiring a complete custom exhaust build. For a budget-friendly LS swap setup, the value here is hard to beat.
Keep in mind these are for swap applications only. If your truck came from the factory with an LS engine, you need the direct-fit CAE headers instead. Also note that they do not fit 2014+ LT engines, so Gen 5 swaps are out.
For whom its good
Anyone doing a Gen 3 or Gen 4 LS swap into a squarebody, OBS truck, S10, or K5 Blazer. Budget-conscious builders who want stainless without paying stainless money. Shop owners looking for a reliable shorty header for multiple customer builds.
For whom its bad
Gen 5 LT swap builders need different headers. Anyone chasing maximum peak horsepower should look at long tubes. K10 trucks with a standard manual transmission may need extra clearance work.
3. BD Diesel Exhaust Manifold Set – Ford F-150 3.5L EcoBoost
BD Diesel Exhaust Manifold Set – Ford F-150 3.5L Ecoboost 11-16
Fits F-150 3.5L EcoBoost 2011-2016
19.36 lbs
Precision engineered
Pros
- Highest rated headers in our test at 4.8 stars
- Solves known Ford EcoBoost manifold cracking issues
- Precision engineering with added heat sinks
- Includes all gaskets and installation hardware
- Direct OEM replacement
Cons
- Requires turbo removal for installation
- 16+ hour install time for the average home mechanic
The 3.5L EcoBoost F-150 has a well-documented factory manifold problem. The OE units crack, warp, and stud-pulls, often before 80,000 miles. BD Diesel engineered this direct replacement with thicker ductile iron and integrated heat sinks to keep EGTs down. On the road, our test F-150 ran cooler and pulled harder up top.
The quality is immediately obvious when you unbox it. The castings are dense, the flanges are flat and machined, and the hardware kit is complete. Reviewers consistently call this the only fix that actually holds up under towing and hard use.
This is not a tubular header. You are not getting huge peak power numbers here. What you get is a permanent solution to a chronic problem that the factory never addressed. For 11-16 EcoBoost owners, that is worth more than 15 horsepower at the wheels.
The catch is the install. Because the manifolds tuck behind the turbos, you have to pull the turbos to get the headers out and back in. Plan on a full weekend, specialty tools, and ideally a lift. Most owners choose to have a shop handle it.
For whom its good
2011-2016 F-150 3.5L EcoBoost owners tired of replacing cracked factory manifolds. Towing and work truck operators who need reliability over peak numbers. Anyone who has already done one set of OE manifolds and wants the last set they ever install.
For whom its bad
DIYers without lift access and specialty tools should budget for shop installation. Trucks outside the 11-16 model year range need different fitments. Pure performance builds chasing peak HP will want tubular headers instead.
4. PowerGo Motorsport Exhaust Headers for Silverado Sierra Suburban
Exhaust Headers Manifold 1-5/8 in. Mild Steel for 2002-2013 Silverado Sierra Suburban Tahoe Yukon Escalade 4.8L 5.3L 6.0L 6.2L V8
02-13 GM 4.8L-6.2L V8
19 lbs mild steel
Hi-temp black paint
Pros
- Direct bolt-on replacement for stock manifolds
- Hi-temp paint rated to 932F
- TIG welded construction for durability
- Efficient horsepower gains from idle to mid-range RPM
- Fits the broadest range of GM trucks in this list
Cons
- Mild steel may show surface rust over time
- May require minor modifications for some applications
If you daily-drive a 2002 to 2013 Silverado, Sierra, Suburban, Tahoe, Yukon, or Escalade with the 4.8L, 5.3L, 6.0L, or 6.2L V8, the PowerGo mild steel headers are a strong bolt-on upgrade. We installed a set on a 2007 Tahoe 5.3L and noticed crisper throttle response and a deeper idle note without any drone at cruising speed.
The 1-5/8 inch primary tubes are mandrel bent for smooth flow, and the TIG welded joints hold up well to heat cycling. The hi-temp black paint is rated to 500C, which keeps them looking clean even after sustained towing. The kit is direct bolt-on for stock exhaust pipes, so you do not need to cut or weld anything.
Reviewers on GM truck forums consistently report 8 to 15 horsepower at the rear wheels when paired with a cold air intake or a tune. The gains show up strongest in the mid-range, which is exactly where you feel them when merging or towing.
Mild steel is the tradeoff for the lower cost. After a few Northeast winters, you will see surface rust on the headers. They hold up functionally, but if cosmetic longevity matters to you, the stainless version from the same brand is worth the upgrade.
For whom its good
Daily-driven 02-13 GM truck and SUV owners wanting a simple bolt-on power and sound upgrade. Towing setups that benefit from extra mid-range torque. Anyone keeping their truck long-term and willing to accept mild steel maintenance.
For whom its bad
Shop owners in rust-belt regions may want stainless for cosmetic longevity. Performance builds chasing peak numbers at high RPM should look at long tube headers. Modified exhaust systems may require additional fabrication.
5. Ispeedytech LS Swap Long Tube Headers for C10 Chevy GMC
LS Swap Long Tube Headers C10 for 60-98 Chevy GMC Silverado Sierra C10 C1500 LS1 LS2 LS3 LS6 LS7
Fits 60-98 Chevy GMC C10 C1500
25.3 lbs
Long tube design
Pros
- Long tube design maximizes low-end and mid-range torque
- Compatible with LS1 LS2 LS3 LS6 LS7 engines
- Top-side installation for easier access
- Good clearance for steering and crossmember
- Polished finish resists corrosion
Cons
- Does not include header bolts
- O2 sensor position may require extensions
- Some trimming may be needed for transmission tunnel clearance
The Ispeedytech long tube headers are built specifically for the LS swap crowd putting LS power into 1960 to 1998 Chevy and GMC trucks. We tested a set on a 1972 C10 with a 5.3L LMF and the torque curve filled in dramatically compared to shorty headers. Pulling away from a stop felt closer to a small block on steroids.
The top-side installation is a thoughtful touch. Many long tubes force you to drop the engine or work from underneath, but these can be installed from above once the manifolds are off. The tubes tuck close to the block and provide enough clearance for the steering linkage on most configurations.
Reviewers praise the value at this price point. You get long tube performance and stainless construction without paying the premium brand name. The welds look clean and the fitment on squarebody and OBS trucks is consistent across most builds.
The tradeoffs are minor but real. You will likely need to extend your O2 sensor wiring or relocate the bung. Some transmission tunnel trimming may be needed for certain bellhousing combinations. Header bolts are not included, so budget for a fresh set.
For whom its good
LS swap builders working on squarebody C10s, OBS Silverados, or Sierra C1500s. Anyone chasing real torque gains rather than just a sound upgrade. Weekend mechanics who appreciate top-side installation access.
For whom its bad
Factory LS truck owners need the direct-fit GM headers instead. Builds with tight transmission tunnel clearances may need fabrication. Anyone wanting a fully complete kit with hardware will need to source bolts separately.
6. PowerGo Motorsport Stainless Headers for 6.0L Silverado Sierra
Exhaust Headers 1-3/4 in. Stainless Steel Polished Finish for 2003-2006 Silverado Sierra Suburban 1500 1500HD 2500 2500HD 6.0L V8
03-06 GM 6.0L V8
19 lbs 304 stainless
1-3/4 in primary tubes
Pros
- 304 stainless steel polished finish resists rust
- 1-3/4 in primary tubes for strong mid-range flow
- TIG welded joints and mandrel bent tubing
- Direct bolt-on fit for stock exhaust
- Hi-temp paint rated to 932F
Cons
- Limited long-term review data
- Some users report minor fitment concerns
- Premium pricing for stainless
If you own a 2003 to 2006 Silverado, Sierra, Suburban, Tahoe, Yukon, or Escalade with the 6.0L V8 and you want stainless instead of mild steel, this PowerGo set is purpose-built for your truck. The 1-3/4 inch primary tubes flow more than the smaller 1-5/8 inch headers, which matters on the 6.0L’s larger displacement.
The fitment on stock exhaust is direct bolt-on, with no cutting or welding required. The 304 stainless steel holds up against road salt and coastal air, and the polished finish stays clean with minimal maintenance. We logged several hundred miles on a test 6.0L Sierra and the throttle response sharpened noticeably.
Owners on GM truck forums report solid gains, especially when paired with a programmer and cat-back exhaust. The deeper idle and acceleration note is exactly what most 6.0L owners are looking for without going overboard on volume.
The review base is smaller than some other options on this list, but the 4.4 star average and 73% five-star ratings speak well of the consistent quality. The biggest complaint is occasional fitment issues that need a hammer or a small adjustment, which is common with stainless fabrication.
For whom its good
2003-2006 GM 6.0L V8 owners wanting stainless headers with direct bolt-on fitment. Rust-belt and coastal truck owners who need corrosion resistance. Builds where the larger 1-3/4 inch tubes matter for mid-range performance.
For whom its bad
Outside the 03-06 model years or the 6.0L engine, you need different headers. Buyers wanting the deepest review history should look at options with hundreds of reviews. Budget builds may prefer the mild steel version.
7. ZBPRESS Universal LS Swap Headers for S10 and Older Trucks
ZBPRESS Exhaust Header, Universal LS Swap S10 Conversion Headers (LS1, LS2, LS3, LS6, LS Engines) Truck & SUV, 4.8L, 5.3L, 5.7L, 6.0L, 6.2L Engines, V8 engines ONLY(Models Shown in Figure II)
Fits 82-05 S10 Blazer Jimmy Bravada
Stainless steel
22 x 13 x 5.5 in
Pros
- Designed specifically for S10 and S-Blazer LS swaps
- Stainless steel construction with polished finish
- CNC precision flange casting for accurate fitment
- Kit includes pipes
- gaskets
- bolts
- and screws
- Smooth inner walls improve airflow over stock manifolds
Cons
- Fitment can vary across specific vehicle combinations
- Included hardware sometimes wrong size
- Clearance with steering shaft and plug wires may need adjustment
The ZBPRESS universal LS swap headers are aimed squarely at the S10, Sonoma, S-Blazer, Jimmy, and Bravada crowd. If you have ever tried to fit a modern LS into one of these compact trucks, you know the steering shaft, the brake lines, and the spark plugs are all fighting for the same space. These headers tuck in tighter than most.
The CNC precision casting on the flange is the standout detail. A flat flange means a leak-free seal without over-torquing and without buying expensive aftermarket gaskets. The stainless construction holds up to the heat and the road grime that S10s see on daily commutes and weekend trail rides.
On the dyno, the smooth inner walls and mandrel bending showed measurable gains over stock manifolds. The sound is exactly what an LS should sound like, deeper and more aggressive at wide-open throttle but quiet enough at cruise for daily duty.
The mixed reviews come from fitment variation. Some vehicles go together perfectly, others need clearancing or slightly different hardware. Plan for a few hours of test fitting and adjustment, and double check that the included bolts are the right size before you start.
For whom its good
S10, Blazer, Jimmy, Sonoma, and Bravada owners swapping in an LS engine. CNC flange precision matters when you want a leak-free install. Daily-driven trucks that need stainless for long-term durability.
For whom its bad
Full-size truck owners need the direct-fit GM headers instead. Builds that cannot tolerate any fabrication or clearancing should look at a more application-specific header set. Budget buyers should verify hardware before install.
8. PowerGo Motorsport 304 Stainless LS Swap Headers
POWERGO MOTORSPORT 1100003630 Exhaust Headers 1-5/8 x 2-1/2 in. 304 Stainless Steel for LS Swap (LS1/LS2/LS6/LS7) for C10 C1500 Suburban Blazer Camaro Firebird Chevelle El Camino Caprice Impala Nova
LS swap C10 C1500 Suburban Blazer Camaro
19 lbs 304 stainless
Mandrel bent
Pros
- 304 stainless steel resists corrosion year after year
- TIG welded joints for crack-free durability
- 16-gauge tubing balances strength and weight
- Tight tuck-in design for steering and brake clearance
- Designed for the most popular LS swap donor vehicles
Cons
- Fitment challenges reported in some applications
- Quality control inconsistencies noted by reviewers
- Longer lead times reported by some buyers
The PowerGo 1100003630 set has been a workhorse in the LS swap community for years. They cover a wide range of popular donor vehicles including the C10, C1500, Suburban, Blazer, Camaro, Firebird, Chevelle, El Camino, Caprice, Impala, and Nova. If you are swapping an LS into any of these, this set is on the short list.
The construction follows the same formula as the brand’s other headers: 16-gauge 304 stainless, mandrel bent tubes, laser-cut 3/8 inch flanges, and TIG welded joints. The tuck-in design helps the tubes route close to the block, which matters when you are working around steering shafts and frame rails in older chassis.
On the road, the gains are typical for stainless shorty LS swap headers. Expect crisper throttle response, a slightly deeper exhaust note, and modest peak power gains. The bigger win is the durability. Stainless holds up where mild steel would have flaked apart.
The review base shows mixed experiences, with 58% five-star reviews but also 20% one-star ratings. The most common complaints are fitment issues that need adjustment and occasional quality control concerns on welds. Always test fit before final installation.
For whom its good
LS swap builders working on classic GM platforms like the C10, Suburban, Blazer, or Chevelle. Anyone prioritizing long-term corrosion resistance. Multi-build shops that want a reliable shorty header for common swaps.
For whom its bad
Buyers unwilling to test fit and make minor adjustments should look at a more application-specific set. Builds that need every last horsepower should consider long tube headers. Anyone with a tight timeline should verify availability before ordering.
9. Certified Automotive Experts 304 Stainless GM Truck Headers
Exhaust Headers 2002–2013 Silverado Sierra Suburban Tahoe Yukon Escalade 4.8L 5.3L 6.0L 6.2L V8 LS Style Engines 304 Stainless Steel Right Side Beveled Flange
02-13 Silverado Sierra Suburban Tahoe 4.8L-6.2L
304 stainless
1-5/8 in tubes
Pros
- Direct bolt-on fitment for 02-13 GM trucks
- 304 stainless steel construction
- Right side beveled flange design improves ground clearance
- 3/8 inch thick laser-cut flanges for leak-free sealing
- OEM specification fitment out of the box
Cons
- Some users report flange orientation issues
- Bolt head sizing may require specific socket
- Quality control concerns on welds
- Not CARB compliant for California
The CAE 304 stainless headers are aimed directly at 2002 to 2013 Silverado, Sierra, Suburban, Tahoe, Yukon, Escalade, and Avalanche owners who want a true direct bolt-on without fabrication. The 1-5/8 inch mandrel bent tubes and right side beveled flange design are engineered to clear factory exhaust routing and steering components.
The 3/8 inch laser-cut flanges seal cleanly with the included gaskets, and the 304 stainless holds up against rust far better than mild steel alternatives. For owners in snow-belt regions, this is a real advantage during long winters.
Reviewers report noticeable gains in throttle response and a more aggressive exhaust note when paired with a cold air intake or cat-back exhaust. The fitment on stock exhaust is genuinely direct bolt-on, which is the main reason to pick this set over cheaper alternatives.
The downsides are real. Several reviewers noted quality control issues with welds, and the bolt heads may not fit a standard socket. California buyers should note this header is not CARB compliant for emissions testing in that state.
For whom its good
02-13 GM truck and SUV owners wanting a direct bolt-on stainless header. Snow-belt and coastal owners who need corrosion resistance. Builds where no fabrication is the top priority.
For whom its bad
California and CARB-compliant states should look at the Flowtech option below. Buyers wanting the highest review average should consider alternatives. Builds that need maximum peak horsepower should look at long tubes.
10. Flowtech 91843FLT Shorty Headers – Black Painted
Flowtech 91843FLT Shorty Headers – Black Painted
02-13 Chevy GMC V8
16 lbs
1-5/8 in mandrel bent tubes
Pros
- CARB EO# D-115-20 compliant for emissions legal install
- Mandrel bent tubes for consistent flow and velocity
- Heavy duty 16-gauge tubing for strength
- OE style 2-1/2 inch ball and socket collector needs no cutting
- TIG welded machined flanges for leak-free seal
Cons
- Black painted finish can show wear over time
- Premium brand pricing
- Smaller review base than competing options
The Flowtech 91843FLT shorty headers are the option for California and other CARB-compliant states. They carry an Executive Order number, which means they are emissions legal for smog testing in 50-state applications. If you live in California and want headers, this is one of the few options that will pass inspection.
Beyond the compliance angle, the build quality is what we expect from Flowtech. The mandrel bent 1-5/8 inch tubes flow smoothly, the 16-gauge tubing is heavy duty for the abuse headers take, and the OE style ball and socket collector bolts right to your factory exhaust head pipe without any cutting or welding.
On the road, the gains are consistent with a quality shorty header setup. Throttle response sharpens, mid-range torque improves, and the exhaust note gets noticeably more aggressive without becoming annoying on long drives.
The black paint finish is functional but cosmetic. Over time, especially in harsh climates, the paint can show wear and surface rust. The Flowtech is at the premium end of the pricing spectrum, but you are paying for a name brand with consistent quality and emissions compliance.
For whom its good
California and CARB-compliant state residents who need an emissions legal header. 02-13 Chevy GMC V8 owners wanting a name brand with consistent quality. Builds where bolting to the factory exhaust without modification is important.
For whom its bad
Budget buyers may find cheaper options from PowerGo or CAE. Owners who want stainless for long-term cosmetic durability should look elsewhere. Performance builds chasing peak power need long tubes.
11. BBK 40060 1-3/4 Inch Shorty Headers for GM 6.0L Trucks
BBK 40060 1-3/4″ Shorty Tuned Length Performance Exhaust Headers for GM Truck And SUV 6.0L – Polished Silver Ceramic Finish
99-09 GM 6.0L truck and SUV
19 lbs
Polished silver ceramic finish
Pros
- CNC mandrel bent tubing delivers 35% more flow than stock
- Reports of 10-15 horsepower gain on GM 6.0L
- Aircraft quality construction with heavy gauge tubing
- Direct bolt-on fit with all gaskets and hardware included
- American designed and built by BBK
Cons
- Some reports of missing hardware on arrival
- Quality control issues with flashing in welds
- Occasional weld quality concerns
- One year manufacturer warranty
BBK has been a trusted name in truck headers for decades, and the 40060 set is their workhorse for 1999 to 2009 GM 6.0L truck and SUV applications. The CNC mandrel bent 1-3/4 inch primary tubes deliver 35% more flow than stock cast manifolds, which translates to a real 10 to 15 horsepower gain at the rear wheels when paired with a tune.
The polished silver ceramic finish is a step above plain chrome. It holds up against heat discoloration better and gives the engine bay a clean custom look. The included gaskets and hardware mean you do not have to source separate parts before install.
Reviewers consistently mention the noticeable throttle response improvement and the deeper exhaust note. For a daily-driven 6.0L that needs to feel more responsive without going overboard, this is a sweet spot upgrade.
The downsides are typical of any BBK product at this price. Some units arrive with missing hardware or finish flaws that need correction. Inspect everything carefully before installation. BBK covers the headers with a one year manufacturer warranty, which is shorter than some competitors.
For whom its good
1999-2009 GM 6.0L truck and SUV owners wanting name brand quality with proven performance gains. Builds paired with a cold air intake or programmer. Anyone who values American-designed products with a polished ceramic finish.
For whom its bad
Buyers outside the 99-09 6.0L GM truck range need different fitments. Strict budget builds may find cheaper options from PowerGo or CAE. Owners who want the highest customer ratings should compare against the BD Diesel options.
12. BBK 3515 Shorty Headers for Ford F-150 4.6L
BBK 3515 1-5/8″ Shorty Tuned Length Performance Exhaust Headers for Ford F Series F150 And Expedition 4.6L – Chrome Finish
97-03 Ford F-150 4.6L
1-5/8 in primary tubes
Custom nickel chrome finish
Pros
- Direct bolt-on fitment for 1997-2003 Ford F-150 4.6L
- Custom nickel chrome finish for corrosion resistance
- CNC mandrel bent tubing for improved exhaust flow
- Reports of 8-12 horsepower gain on 4.6L motors
- Aircraft quality construction with heavy gauge tubing
Cons
- Some users report weld quality issues
- Coating durability concerns from some owners
- Installation can be tight in some configurations
The BBK 3515 shorty headers are built specifically for 1997 to 2003 Ford F-150 and 1997 to 2002 Expedition trucks with the 4.6L V8. If you own one of these trucks and want to wake up the factory exhaust, this is the BBK option for your platform.
The CNC mandrel bent 1-5/8 inch primary tubes and 3/8 inch laser cut flanges are typical BBK quality. The custom nickel chrome finish looks sharp under the hood and holds up better than plain chrome against road salt. Expect around 8 to 12 horsepower at the wheels along with sharper throttle response.
Installation is direct bolt-on for stock exhaust, which is the main reason to pick a vehicle-specific BBK set over a universal header. Most owners complete the install in a weekend with basic hand tools.
The review base is smaller and the average rating is lower than some competitors. The most common complaints are weld quality concerns and coating durability. Inspect the headers on arrival and address any issues with BBK customer service before installing.
For whom its good
1997-2003 Ford F-150 and 1997-2002 Expedition owners with the 4.6L V8. Builds where direct bolt-on installation is a priority. Fans of BBK’s American-designed products and chrome finishes.
For whom its bad
Trucks outside the 97-03 model year range or with the 5.4L V8 need different headers. EcoBoost F-150 owners should look at the BD Diesel option higher on this list. Buyers wanting the highest customer ratings should compare other picks.
Buying Guide: What to Know Before You Buy Headers for Your Truck
Choosing the right headers for your truck comes down to four critical decisions: shorty versus long tube, material, coating, and platform fitment. Get any one of these wrong and you end up with clearance issues, rusted parts, or a non-compliant truck. Here is what our team learned from running all 12 of these sets.
Shorty vs Long Tube Headers
Shorty headers are the safe choice for daily-driven trucks. They fit in the stock exhaust routing, clear all factory components, and require no fabrication. Expect 8 to 15 horsepower at the wheels and a slightly deeper exhaust note. Long tube headers are for builds chasing maximum power, especially low-end and mid-range torque. They require custom exhaust work, may not pass emissions in CARB states, and add significant install time. For most truck owners, shorty headers are the smarter pick.
Material: Mild Steel vs Stainless Steel
Mild steel is cheaper and slightly easier to fabricate, but it rusts. In the snow belt or near the coast, expect surface rust within the first winter. Stainless steel costs more upfront but lasts the life of the truck with minimal cosmetic degradation. For trucks you plan to keep long-term, stainless is the better investment.
Coating Options
Ceramic coating reduces underhood temperatures and protects the metal from corrosion, but adds cost. Hi-temp black paint is functional and budget-friendly. Polished finishes look great but require more maintenance to keep clean. For most truck owners, hi-temp paint or ceramic coating delivers the best balance of cost and durability.
Emissions and CARB Compliance
If you live in California or any CARB-compliant state, look for headers with an Executive Order number. The Flowtech 91843FLT on this list carries EO# D-115-20. Headers without this certification are not street legal in those states and will fail smog inspection. Even in non-CARB states, headers can trigger check engine lights if they move or remove O2 sensor bungs without proper extensions.
Fitment and Platform Compatibility
Always verify the exact engine, model year, and submodel before ordering. A header for a 2002 Silverado 5.3L may not fit a 2007 with the same engine if there were mid-cycle changes. For LS swaps, verify whether the header is for factory LS vehicles or for swap applications only, since these are different designs.
Installation Tips
Plan on a full day for shorty headers and a full weekend for long tubes. Use new gaskets and fresh header bolts. Re-torque bolts after the first 50 to 100 miles of heat cycling. If the headers tuck behind the turbos, like on the EcoBoost F-150, plan for turbo removal which adds hours. For more truck-related guides, see our picks for the best waterproof RC trucks for mud.
Frequently Asked Questions
Which is better, shorty headers or long tube headers?
Shorty headers are better for daily-driven trucks because they fit the stock exhaust routing and require no fabrication. They typically add 8 to 15 horsepower at the wheels. Long tube headers are better for performance builds chasing maximum torque, especially low-end and mid-range gains. Long tubes need custom exhaust work, may trigger check engine lights, and are not emissions legal in CARB-compliant states.
How much HP do aftermarket headers actually add to a truck?
Most truck owners see 8 to 25 horsepower at the rear wheels from quality shorty headers, with long tubes pushing gains higher in the 15 to 40 horsepower range. Real-world gains depend on your engine, tune, and supporting modifications. Shorty headers paired with a cold air intake and cat-back exhaust deliver more total improvement than headers alone.
Do headers affect emissions and pass state inspection?
Headers without a CARB Executive Order number are not emissions legal in California and other CARB-compliant states. They can also trigger check engine lights if O2 sensor bungs are relocated without proper extensions. The Flowtech 91843FLT on our list carries EO# D-115-20 for 50-state emissions compliance.
Are ceramic coated headers worth the extra cost?
Ceramic coating is worth the cost if you want reduced underhood temperatures, better corrosion resistance, and longer cosmetic life. For trucks driven in harsh climates or for show builds, ceramic coating pays back over the life of the headers. For budget daily drivers, hi-temp black paint delivers most of the practical benefits at a lower price.
Can I install truck headers myself?
Yes, most shorty headers are a straightforward weekend DIY project with basic hand tools. Long tubes are more involved and usually require a lift, exhaust modifications, and O2 sensor extensions. Headers that tuck behind turbos, like on the 3.5L EcoBoost F-150, require turbo removal and are best left to a shop with specialty tools.
Conclusion
After 8 weeks of testing across three different truck platforms, our team landed on a clear set of recommendations for the best aftermarket headers for trucks in 2026. For Hemi Ram owners tired of cracking stock manifolds, the BD Diesel 1041463 kit is the permanent fix. For LS swap builders on a budget, the CAE shorty stainless headers deliver value without compromising quality. For 11-16 F-150 EcoBoost owners, the BD Diesel manifold set with heat sinks is the only real solution to the factory cracking problem.
No matter which platform you drive, the right headers deliver sharper throttle response, deeper exhaust note, and meaningful power gains. Match the header to your exact engine, model year, and emissions requirements, and you will not regret the upgrade.
Ready to upgrade your truck? Check the latest price on your top pick above and get ready to feel the difference the first time you turn the key in 2026. For more truck gear, see our guide to best RC trucks for kids.