Some 1st gen HO (High Output) Ford Escorts in the 1980s came stock with factory headers. The main advantage to using them is their occasional availability in junkyards. While overall the header design is good, it does require some modification to fit on to a 2nd or 3rd gen Escort. The main issue is they stick out too far from the engine and make contact with the fan shroud and AC lines, both of which have to be modified.

Required modifications for fitment

• EGR system was removed and welded shut (it was sticking out 1/4 in inside the pipe).
• Brackets were removed and new ones created to fit.
• Two pipes were shortened to allow closer fitment to the oil pan and less sticking out beneath the car.
• Some sections bent with heat.

1st gen HO header specs

• All the tubing before the collector is 1 3/4 in.
• The collector is only 2 in or slightly smaller. This would eliminate any benefits from installing a 2 1/4 in exhaust catback. The optimal size for this header is a 2" exhaust.

3rd gen Escort exhaust specs

• The catalytic converter pipe is 2 in.
• After the converter it briefly goes to 1 3/4 in, gets adapted to 2 in for the flex pipe, then back down to 1 3/4 in, and by the time it gets to the muffler its 1 7/8 in.
• The stock muffler input is 1 7/8 in and output is 1 3/4 in.

They should have just used 2 in piping throughout! It must have cost Ford more to use two sizes of pipe and those adapter sleeves instead of one size pipe without adapters. The assembly would have been faster to manufacture as well. The following pictures provide some general examples of the work that has to be done. As the pictures progress, it can be see the various stages that required modification. First the headers had to be angled more downwards to clear all of the engine bay components and sit closer to the engine. Once that was performed the headers pointed up too much in the back so the back part had to be modified to go lower. As of yet, this header has not been test fitted. Pictures of header modification courtesy of feoa.net member madmatt2024.

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Also see

• Ford Escort & ZX2 section for the entire index of all Ford Escort and ZX2 related articles.