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Ford Windsor V8 Header Guide

Ford Windsor V8 Headers Guide: 289, 302, 351 Cast vs Alloy Heads (Pacemaker Extractors)

Expert guide to choosing the correct Pacemaker headers for Ford Windsor V8 engines.

✔ Covers 289, 302 & 351 alloy and cast cylinder heads
✔ Includes recommended Pacemaker header part numbers (other brands included)
✔ Helps you choose the correct headers for fitment and performance

Choosing the correct exhaust headers for your Ford Windsor V8 engine comes down to two critical factors: 289–302 vs 351 and cylinder head design. Whether you're running factory cast iron or aftermarket alloy heads, each requires a specific header configuration to ensure correct fitment, proper exhaust port alignment, optimal exhaust flow and maximum performance.

This guide is based on real-world workshop experience fitting Windsor V8 headers across Australian Ford Falcons, Ford F100s and imported Ford Mustangs for both standard and performance builds.

What’s the difference between Cast Iron and Alloy heads?

Cast iron heads have smaller, narrower exhaust ports designed for strong low- and mid-range torque, making them ideal for street performance driving.
Factory cast iron port dimensions: 25.4mm x 31.5mm
GT40P cast iron port dimensions: 25.4mm x 31.5mm (with different spark plug angle)
Factory exhaust port bolt spacing: 50.8mm

Aftermarket alloy heads have larger, wider ports designed for increased airflow and high-RPM horsepower. These are best suited for performance and racing applications. Brands such as Edelbrock, AFR, Trick Flow and CHI vary in port sizing, but typical ranges are below.

Street performance port dimensions: 32–34mm x 28–32mm
Race performance port dimensions: 34–38mm x 30–35mm
Typically, AFR, Dart and Ford SVO (Z304) heads feature dual bolt patterns (50.8mm and 76mm). The wider bolt pattern allows larger primary pipes and improved bolt access.

Which headers do I need for my Windsor V8 engine?

Cast iron heads: PH4010, PH4020, PH4025, PH4032, PH4033, PH4000, PH4001, PH4006, PH4035, EXT457, EXT448
Aftermarket alloy heads: PH4036, PH4038, EXT457D, EXT448D
Note: Some alloy heads retain the factory bolt pattern, while others include both standard and wider bolt patterns.

Quick Comparison: 289–302 and 351 Windsor Cast vs Alloy Heads

Head Type Port Design Best For Header Requirement
Cast Small port Street / Torque Cast iron-specific headers
Cast (GT40P) Small port (high velocity) Street / Performance Cast iron-specific headers
Alloy Large port Performance / Racing Dedicated alloy headers

🔧 Cast Iron Heads (Small Port)

Best for: Street performance, strong torque, daily driving

  • Smaller intake and exhaust ports
  • Higher air velocity for improved low- and mid-range torque
  • Common across many Australian-delivered Falcons

Recommended Pacemaker Headers:

Fitment Notes:

  • PH4010: No fitting issues
  • PH4020: No fitting issues
  • PH4025: No fitting issues
  • PH4032: No fitting issues
  • PH4033: No fitting issues
  • PH4000: No fitting issues (direct-fit high-flow cats available)
  • PH4001: No fitting issues
  • PH4006: Check clearance on left-hand side near engine mount bracket

🔥 Cast Heads (GT40P Heads)

Best for: Strong street performance with improved efficiency over earlier factory castings

  • Small, high-velocity port design
  • Different spark plug angle compared to standard Windsor heads
  • Improved airflow over early cast heads while retaining standard header fitment

Fitment Notes:

  • PH4001: No fitting issues
  • PH4006: Check clearance near engine mount bracket
  • PH4033: No fitting issues
  • Always check engine and gearbox mount condition

🚀 Alloy Heads

Important: Standard Windsor headers are not ideal for alloy heads. While they may physically bolt on, port mismatch can reduce flow and performance unless modified.

Fitment Notes:

  • PH4033: Will require port matching when used on alloy heads
  • PH4036: Check clearance on right-hand side gearbox crossmember
  • PH4038: Check clearance on right-hand side gearbox crossmember
  • EXT457D: No fitting issues (high performance) wide bolt pattern
  • EXT448D: No fitting issues (high performance) wide bolt pattern
  • Always check engine and gearbox mount condition

Why Header Size and Port Match Matter

Airflow demand rises quickly as power increases, and hot exhaust gas occupies far more volume than the intake air that entered the engine. This is why correct header sizing, flange design and port alignment matter so much on Ford Windsor V8 engines.

Approximate airflow guide at 4000 rpm:
A standard 302 Windsor at 4000 rpm draws approximately 8,400L/min of air and expels approximately 25,200L/min of hot exhaust gas.
A Windsor engine making 350hp at 4000 rpm draws approximately 14,900L/min of air and expels approximately 44,700L/min of hot exhaust gas.
A Windsor engine making 450hp at 4000 rpm draws approximately 19,100L/min of air and expels approximately 57,300L/min of hot exhaust gas.
A Windsor engine making 550hp at 4000 rpm draws approximately 23,400L/min of air and expels approximately 70,200L/min of hot exhaust gas.
A Windsor engine making 650hp at 4000 rpm draws approximately 27,600L/min of air and expels approximately 82,800L/min of hot exhaust gas.

These figures help explain why smaller primary pipes often suit mild street combinations for gas speed and torque, while higher-output Windsor engines generally benefit from larger pipes and better flange-to-port matching to reduce restriction.

Common mistakes when choosing Windsor V8 headers

  • Using headers designed for cast heads on alloy heads (and vice versa)
  • Ignoring port size and shape differences
  • Not checking gearbox and chassis clearance
  • Not checking engine and gearbox mount condition
  • Choosing headers without correctly identifying engine size and head type

❓ Frequently Asked Questions

Can I use 302 headers on a 351?
No. The 351 Windsor has a taller deck height, which changes header alignment and fitment.

Do headers designed for alloy heads fit standard cast iron heads?
Not usually as an ideal match. Differences in port shape and bolt pattern mean the correct header should always be selected for the head type.

What happens if I use the wrong headers?
You may experience exhaust leaks, reduced performance and fitment issues.

What size exhaust should I use? (Guide only)
Standard 289–302 engine: Twin 2.25" with either 2.00" or 2.25" tailpipes
Mild 289–302 engine (350–450hp): Twin 3.00" with 2.50" tailpipes
Performance 302–347 engine (450–550hp): Twin 3.00" with 2.50" tailpipes
High-performance 302–347 engine (550–650hp): Twin 3.00" with 3.00" tailpipes
High-performance stroker engine (650–750hp): Twin 3.50" with 3.00" tailpipes
High-performance stroker engine (750–850hp): Twin 3.50" with no tailpipes

Do you supply performance exhaust systems?
Yes — we supply performance exhaust systems for:
Ford Falcons XR–XY: Twin 3.00"/2.50" or full twin 3.00" systems
Ford Falcons XA–XC: Twin 3.00"/2.50" or full twin 3.00" systems
Ford Falcons XD: Twin 3.00"/2.50" systems
Ford Falcons XE: Twin 3.00"/2.50" systems

Customer Support

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Exhaust Systems Since 1983

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