PerTronix JBA Exhaust 1679S-4 - Manual (Page 3)

4. Remove the sheet metal screws that attach the inner fenderwells to the fender and frame of the truck and drop
both inner fenderwells out of the truck.
DRIVER’S SIDE
5. Working through the wheel well, loosen the EGR tube from the manifold. Remove the nuts attaching the
manifold to the head and remove the manifold. Remove the exhaust studs from the head. The studs have a 5mm
hex end on them, use a 1/4” drive ratchet and a 5mm socket to remove.
6. Remove the oil dipstick. It has a separate mounting bolt on the head and uses an O-ring seal at the bottom.
Use care to protect the O-ring.
7. Remove the EGR fitting from the stock manifold and install it into the drivers side header.
8. Remove the gaskets and any gasket material or any carbon deposits that remain on the head surface. The use
of a gasket removal agent or scraper will ease the removal of any gasket material. Use care not to get debris into
ports.
9. Slip the driver’s side header into place from underneath the vehicle. Some twisting and wiggling of the header
is necessary to get the header in place. Apply a small amount of anti-seize to the threads of the supplied header
bolts. Attach the header using the supplied bolts, gaskets and lock washers and torque to 23 ft/lbs.
10. The EGR tube must now be loosened at the EGR valve to allow attaching to the fitting on the header. Once
both ends of the tube are in place, tighten the EGR tube. Re-install the dipstick.
PASSENGER SIDE
11. Working through the wheel well, remove the nuts attaching the manifold to the head and remove the mani-
fold. Remove the exhaust studs from the head. The studs have a 5mm hex end on them, use a 1/4” drive ratchet
and a 5mm socket to remove.
12. Install the passenger side header through the wheel well. Apply a small amount of anti-seize to the threads
of the supplied header bolts. Attach the header using the supplied bolts, gaskets and lock washers and torque to
23 ft/lbs.
13. Apply a small amount of Sensor Safe High Temperature Silicone Sealant to the collector domes and Re-
connect the exhaust system to the new headers using the hardware provided.
14. Re-connect the drive shaft on 4X4 vehicles.
15. Re-install the inner wheel wells. On 4.6L models, it is recommended that you remove the passenger side
wheel well flap.
16. Check to make sure that all the wiring, fuel lines, transmission cooler lines, brake lines, hoses, etc. are clear
of the headers or any exhaust components and reroute or relocate those components as necessary.
17. Re-install the front wheels and torque to factory specs. (See owners manual)
18. Reconnect the battery.
19. Start the engine, check for leaks and test drive. Let the engine cool and then re-torque the header bolts.
20. Periodically check and retighten the header bolts.