1994 Mercury Villager Exhaust Headers and Exhaust Manifolds

Boost your ride’s performance or replace broken exhaust components with RealTruck’s selection of exhaust headers and exhaust manifolds. We offer all the top brands and styles, ranging from performance-oriented tubular headers to factory-style cast-iron manifolds, ensuring proper fitment for your application. 

For product inquiries and order assistance, contact the experts at RealTruck.

Benefits Of Upgrading To Aftermarket Exhaust Headers And Manifolds

Upgrading your truck’s factory cast iron exhaust manifolds to high-flow tubular exhaust headers provides dyno-proven performance benefits and enhanced fuel efficiency. Tubular headers feature mandrel bends and large-diameter tubing to minimize exhaust restriction, allowing your truck’s exhaust gasses to flow out the cylinder heads smoothly and efficiently. More exhaust gasses out equals more air in, and thus, improved performance.

Besides performance, headers can have a massive impact on your truck’s exhaust note, especially when paired with high-flow exhaust systems.

Styles of Exhaust Manifolds and Headers

Exhaust manifolds and headers come in several styles and configurations that offer different performance levels and exhaust notes. Check out some of the most popular varieties below.

Long Tube Headers

Long tube headers enhance engine efficiency and provide a deeper, more aggressive exhaust sound, making them a popular choice among truck enthusiasts seeking a particular performance and sound upgrade. While long tube headers provide better performance benefits over other styles of exhaust manifolds, they also require more extensive modifications to the exhaust and surrounding components for proper fitment. They also tend to run hotter as engine heat dissipates through the long stretches of tubing, requiring additional maintenance and heat shielding.

RealTruck Expert Pick: BBK Performance Long Tube Exhaust Headers

Why we love it: 

• Full-length exhaust headers

• Designed to boost horsepower, torque, and throttle response

• Available in titanium ceramic or polished silver ceramic

• Ceramic coatings reduce heat under the hood

• Made from 16-gauge CNC mandrel-bent steel

• Warp-resistant ⅜-in. thick flanges

• Dyno tested to ensure performance gains

• Includes new gaskets and hardware

• Aggressive sound profile

• Made in the USA

• Limited 1-year warranty

Shorty Headers

Shorty headers provide less significant performance gains. However, they’re typically far simpler to install and require less maintenance/modifications. Several shorty headers feature a direct bolt-on design, including OE-style flanges that accept your vehicle’s factory exhaust system or bolt-on aftermarket systems.  

Shorty headers are also typically more affordable and don’t require any additional piping or labor besides simply bolting them on.

RealTruck Expert Pick: BBK Performance Shorty Exhaust Headers

Why we love it: 

• Short tube exhaust headers

• Designed to boost horsepower, torque, and throttle response

• Available in titanium ceramic or polished silver ceramic

• Ceramic coatings reduce heat under the hood

• Made from 16-gauge CNC mandrel-bent steel

• Warp-resistant ⅜-in. thick flanges

• Dyno tested to ensure performance gains

• Includes new gaskets and hardware

• Deep, throaty sound profile

• Made in the USA

• Limited 1-year warranty

Exhaust Header Vs. Exhaust Manifold

So, what are the primary differences between exhaust manifolds and headers? Both products carry out the same task of directing hot exhaust gasses out of the cylinder heads and into the remainder of the exhaust system. However, they feature different constructions and designs. 

Regarding manufacturing, headers are conventionally constructed from a flat flange and several pieces of mandrel-bent or pie-cut tubing that converge into a single collector, forming a path for exhaust gasses to escape. On the other hand, exhaust manifolds are cast from a single piece of cast iron with built-in pathways for each cylinder. 

Performance-wise, exhaust headers tend to flow better, thus increasing horsepower, torque, and fuel efficiency. Headers are also typically louder, producing the throaty, aggressive exhaust note that enthusiasts desire. 

While headers have several benefits, they also have a couple of drawbacks. Headers are pricier than factory-replacement exhaust manifolds. They also tend to require more maintenance, making them better suited for weekend drivers and project vehicles rather than daily drivers.

RealTruck Expert Pick: aFe BladeRunner Exhaust Manifold

Why we love it: 

• Stainless steel or ductile iron construction

• Higher flow manifold

• Thicker, stronger construction

• Improved turbo spool-up times

• Improved throttle response and performance

• Port matched

• Exhaust flow optimized collector

• Made in the USA 

• 2-year warranty

What Are Exhaust Headers and Manifolds Made Of?

Both exhaust headers and manifolds are constructed from heavy-duty alloys. Headers are typically constructed from ceramic-coated or chrome-plated steel or stainless steel, offering exceptional corrosion and heat resistance for years of reliable service. Exhaust manifolds, on the other hand, are cast from durable iron. In most cases, exhaust manifolds are left raw due to the thickness of the material better tolerating rust and corrosion.