Can I drill it out? Yes. But I shouldn't have to. And, they told me not to for obvious reasons. But if it works who cares.

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2000 XLT supercab, 4x4 7700lb. package, 5.4L, 3.73 LS, CD changer, Flowmaster,Superchip, Airaid, Gibson Headers, Island Blue

 

I agree that you shouldn't have to...

But, if you believe it will work and it saves you a ton of head-aches and shipping charges, I say go for it. It may even be possible to take a file and "knock" the slag loose... if it really is just slag. If it still doesn't work, throw the slag into the packaging when you return the headers and tell them it must have fallen off in transit.

Good luck!

 

So installed Gibson Headers on my Y2k 150. But I keep getting a check engine light which turns out to be inadequate airflow through the EGR. Turns out the EGR tube that's welded in the header is welded off center which is obscuring the inlet by about 50%. So Gibson, after many phone calls, sent out a new header. On the replacement header the excess weld slag has closed off the EGR tube into the collecter from 1/2inch to 1/8inch. Yes the replacement looks worse. Gibson says it should work and if it doesn't they will honor the returned headers with no labor allowance if the headers meet their design spec.
Gibson told me, after many phone calls, they may just not work on my vehicle.
Does anyone have any insight or suggestions?

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2000 XLT supercab, 4x4 7700lb. package, 5.4L, 3.73 LS, CD changer, Flowmaster,Superchip, Airaid, Gibson Headers, Island Blue

 

Can you drill it out?

 

I have a set of JBA headers and they work fine, I have never had a problem with the egr tube, I did look at it though before I put them on and it wasn't closed off. I don't see why they would say that they might not work on you truck, didn't they ever test the headers on a f150 before they sold them?!?! Well anyways, maybe you can send them back and get JBA, they work.

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99 black f150 ext. cab sport w/4.6 V8. external mods. include:
airaid FIPK, JBA headers, Superchip headlight/taillight covers, wiper schroud, shadeblade, ventshade, bug deflector, bed liner, tonno cover, and Flowmaster Amarican Thunder cat-back system.
internal mods. include:
Pioneer indash cdplayer, 2 8" MTX subs, 400 watt amp, remote start, and aftermarket alarm

 

Well I now have the replacement header installed and it works fine. Although, I did machine out the weld slag where it enters the collecter.
As it turns out, on the defective header they never opened the outlet into the collecter. It just deadheaded to nothing. No wonder there was no EGR flow! I made three more calls to Gibson today only to learn that there was no one there who could help me. I was told to call back on Friday.
They will pay for the shipping but the labor reimbursement aspect is still out for debate.

christrucker- they told me they did test the headers on a 2000 5.4. Thanks for the JBA info. Hind-sight is 20/20!

The headers do work and they seem to be well built, other than the EGR set-up being alittle rough. I wouldn't discourage anyone from installing them, just inspect them FIRST more carefully than I did.

On to the Supercharger!


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2000 XLT supercab, 4x4 7700lb. package, 5.4L, 3.73 LS, CD changer, Flowmaster,Superchip, Airaid, Gibson Headers, Island Blue