I am going to do a stock rebuild on my 96 4.0, has anybody here ran headers on their 4.0? What is the best set to buy and where can I get them at? Is there any that are direct bolt on without having to modify the exhaust?

What is a quality performance catalytic converter and muffler, I want quiet not loud.

Should I get a new harmonic balancer with my rebuild kit? Should I balance the rotating assembly?

Is the block of the 4.0 sleeved and should I re-sleeve the cylinders and put in stock pistons or do I bore the cylinders and put in over sized pistons and rings?

 

As far as the exhaust, my APN header has been great. Definitely an improvement. Cheap too. For a good cat, mufflers, and mandrel bent tail-pipes for a good price, check out the vendor mudfrog. Performance-curve.com is his site. Great stuff and service.

Always replace the harmonic balancer if its old. And as far as I know, the stock 4.0 block is not sleeved. Good luck on the rest! Somebody more knowledgeable will chime in.