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i installed thorley tri-y headers on my 1995 E350 in 1998. cracked manifolds and broken studs were also found. after install retorque is a must. never a problem from the headers. my van had a single 2.5" in/out on the cat. front and rear of cat is cone shaped so we backed up til the cone was 3" and cut and welded new in/out to make it a 3" complete system. biggest/best improvement tho was adding an msd 6a. hills that it would downshift to go up it now didn't need to.
 

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forgot to mention, the air filter used on the '95 E350's is the same used on ford pintos. might explain why the filter media kept disappearing from my k&n filters til i pitched the oem airbox and installed a much larger filter to match the bigger throttle body.

on the mileage front as i tow a 3 axle trailer w/ a fairly heavy boat, i would like to do water/meth inj tied to high vacuum conditions (like fwy cruising) and matched by the ecm leaning out the mixture. thinking the octane bump from methanol should cover the lean condition esp in light load conditions. want to do sequential inj first tho
 

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To the OP, I guess your mileage under the same conditions will go up approximately .5 to 1 mpg. The biggest contributor will probably be reduced exhaust back pressure.
 

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duh, i get 12mpg. towing not towing empty full. 12mpg. b4 any mods, 10mpg (on cali reg pump gas)..headers/exh and msd were the big contributors. have read, and would like to believe, going to sequential from batch fire will net another 2... somtime next year will send out heads and intake to the mad porter. in the middle of E4OD to ZF5 swap now. van rides on 20's but total od w/in 1/2" of stock and PSOM reprogrammed to match so i trust the mpg numbers
 

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So...

My 1995 Ford e350 class c has had two broken exhaust manifold bolts for a little while. Also, I got 6 miles per gallon fully loaded and towing a 3200 lb car 2100 miles.
These big blocks (7.5l 460)are notorious for breaking those bolts and there's only one permanent fix. Headers. And there's only one company in the world that makes them anymore for this application - Doug Thorley.

I want more power, better mpg, and a permanent fix so beside just the headers, I'm going all out (with bolt ons).

After the headers, a 3" single exhaust with a BIG Magnaflow muffler. (there is no cat) Freer flowing air intake, restrictors opened up, and a k&n filter. 225lph fuel pump, adjustable fuel pressure regulator and gauge (set at 46lbs) and 26lb injectors. Timing advanced to 12 from 10. Msd coil and 8.5mm wires along with iridium spark plugs. Misc. new valves and sensors and a Banks Transcommand for the E4OD.

I expect better hp, torque, and staying off the gas pedal, better mpg as well. I have no idea what the final numbers will be - maybe someone can give me a good idea...?

I will update in late December after I have a chance to drive it a couple of hundred miles to my next destination
One possible big simple cheap upgrade that seems to be overlooked is replacing the timing chain and gears with a set that has an option key way crank gear for an 8 deg advance, this translates to a 4 deg cam advance.
I did this for my 96 351w e350 during a water pump change I needed to also replace the timing chain cover gaskets. With 115k I found the oem chain had slack and I didn’t want it to break on me in the future as I pass 200k. So I found a high quality Coyles “true street” I think it was called for only $40 on rockauto.
I compression tested before and after one cylinder and found a 20 psi increase.
Some crank gears can advance more. Supposedly some will keep advancing till the highest psi is reached by valves closing earlier on the compression stroke.
Because in about 1972 they retarded the gears for emissions. Had to reset ignition timing of course.
My van is more responsive and torquey. I can’t speak for mileage as I haven’t owned it long and just fixed a fuel tank filler hose leak.
Take care
 

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Discussion Starter · #27 ·
So...

My 1995 Ford e350 class c has had two broken exhaust manifold bolts for a little while. Also, I got 6 miles per gallon fully loaded and towing a 3200 lb car 2100 miles.
These big blocks (7.5l 460)are notorious for breaking those bolts and there's only one permanent fix. Headers. And there's only one company in the world that makes them anymore for this application - Doug Thorley.

I want more power, better mpg, and a permanent fix so beside just the headers, I'm going all out (with bolt ons).

After the headers, a 3" single exhaust with a BIG Magnaflow muffler. (there is no cat) Freer flowing air intake, restrictors opened up, and a k&n filter. 225lph fuel pump, adjustable fuel pressure regulator and gauge (set at 46lbs) and 26lb injectors. Timing advanced to 12 from 10. Msd coil and 8.5mm wires along with iridium spark plugs. Misc. new valves and sensors and a Banks Transcommand for the E4OD.

I expect better hp, torque, and staying off the gas pedal, better mpg as well. I have no idea what the final numbers will be - maybe someone can give me a good idea...?

I will update in late December after I have a chance to drive it a couple of hundred miles to my next destination
Sorry so long for the follow up...

I get a full 2mpg better towing and not towing. I'm very happy with those results!
 

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One possible big simple cheap upgrade that seems to be overlooked is replacing the timing chain and gears with a set that has an option key way crank gear for an 8 deg advance, this translates to a 4 deg cam advance.
I did this for my 96 351w e350 during a water pump change I needed to also replace the timing chain cover gaskets. With 115k I found the oem chain had slack and I didn’t want it to break on me in the future as I pass 200k. So I found a high quality Coyles “true street” I think it was called for only $40 on rockauto.
I compression tested before and after one cylinder and found a 20 psi increase.
Some crank gears can advance more. Supposedly some will keep advancing till the highest psi is reached by valves closing earlier on the compression stroke.
Because in about 1972 they retarded the gears for emissions. Had to reset ignition timing of course.
My van is more responsive and torquey. I can’t speak for mileage as I haven’t owned it long and just fixed a fuel tank filler hose leak.
Take care


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I decided to upgrade the accumulator valve body from Dieselsite and skip the Transcommand and add an Intellitronix ignition. Stock plugs are gapped at .044 - I increased that to .049. Intellitronix suggests opening in increments of .005 at a time until it feels right - I'm not taking those plugs out again for a long time so that's going to have to work.
I see that Intellitronix is a USA made MSD.. didn't think you could install those on an ECM vehicle.
 

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So...

My 1995 Ford e350 class c has had two broken exhaust manifold bolts for a little while. Also, I got 6 miles per gallon fully loaded and towing a 3200 lb car 2100 miles.
These big blocks (7.5l 460)are notorious for breaking those bolts and there's only one permanent fix. Headers. And there's only one company in the world that makes them anymore for this application - Doug Thorley.

I want more power, better mpg, and a permanent fix so beside just the headers, I'm going all out (with bolt ons).

After the headers, a 3" single exhaust with a BIG Magnaflow muffler. (there is no cat) Freer flowing air intake, restrictors opened up, and a k&n filter. 225lph fuel pump, adjustable fuel pressure regulator and gauge (set at 46lbs) and 26lb injectors. Timing advanced to 12 from 10. Msd coil and 8.5mm wires along with iridium spark plugs. Misc. new valves and sensors and a Banks Transcommand for the E4OD.

I expect better hp, torque, and staying off the gas pedal, better mpg as well. I have no idea what the final numbers will be - maybe someone can give me a good idea...?

I will update in late December after I have a chance to drive it a couple of hundred miles to my next destination
I was looking for someone in the 460-gas section about camshaft installs! But on your class c with 460, I stalled a Melling in a 1995 1500 Yukon 4x4, that worked well, cam was a 327-300 hp grind that worked well with EFI system, and pass smog test in Arizona. look for a 460-towing cam, Lunati Cams has some towing cams, and buy a kit with cam lifters and springs,
 
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